Manager Plant

AUM

Om Prakash Mahto

B.E. (Chem.) I I T Roorkee,

M. Tech. (Chem.) I I T Kharagpur

********@*****.***

Tel.No. 772-***-****

GIDC, Ankleshwar Gujarat

Overview

Head Operations & Unit Head

Over 18 Years of Experience as Unit Head / GM / Sr. G M / COO

Expertise in Manufacturing, Projects & Process Engineering

Chemical, Petro, API Bulk drug, Advance Pharma

& Dye intermediates, Polymers, Fine & Agro Chemicals

Continuous process DCS based Units with c GMP, KFDA, WHO, GPCB,

CPCB, ISO, IMS, LEAN, 5 S, MoEF, FAC.ACT, PESO, EC, EHS, SAP, Labour, Factory etc.

Committed to Enhance Productivity & continual total improvement with ownership &

Setting up world class standards of Manufacturing, Projects & Productivty .

Vision

To increase the investors’ value and maximizing profit by improving the operational efficiencies and maximum utilization of the available resources.

Career objectives

A challenging Management position in a fast paced environment to achieve Organizational goals while allowing my personal growth and career advancement to meet my professional excellence, competencies, capabilities, skills, education & experiences.

Career profile Synopsis

30 years of experience of operation of successfully managing all aspects of a large Continuous Chemical, Petro Chemical, Pharmaceutical API Bulk drug, Polymer, fine Chemical with latest technology with PLC, DCS, SCADA based Process control and leading cross-functional teams on key projects.

Wide experience in operations of Petro Chemical plants with exothermic reactions, CSTRs, Cat . Crackers, Heat recovery systems, Continuos distillation units of multi columns, Spray drier, GLR, Centrifuges, Coninuous Crystalizers, FBD, TD, Coal gasifier, Air dryers, Neutche filters, Ozonators, Grannulaters, VAM, Chillers, Membrane Cells, Air Separation units, MEE, Vacuum Ejectors, Pusher / basket centrifuge, Carbon filter, Molecular sieve, Dryer, Hydrogenators, Chlorinators and many other plants, Melters, Digesters, Reactors, CF, Blender, RCVD, Furnaces and Condensers, All type of Heat Exchangers, Re boilers, dryers etc.

Well versed and basic knowledge of Turbine, Cooling tower, DM water, RO, UF filters, Boilers, HVAC, Compressors, Various packing M /cs etc.

Ensuring effective Business Monthly Review meeting ( BMR ) & Continuous improvement programme .

Monitoring, guiding and Control of team consisting Process, Mechanical, Instrument, Electrical, Utilities and Civil .

Ensuring Continuity of Operation & best plant availability, debottlenecking & trouble shooting .

Ensuring Operations to maximize efficiency by Cost effectiveness, Consumptions & Variable costs reductions.

Always ensuring Hazop & cost benefit analysis before modifications and documentation implementation.

Establishing Customer Relationships on Product Quality on behalf of the company.

Adhering Optimum operating parameters and implementing CAPA as per requirements.

Responsible for each and every activity of plant including production, QC, QA, Engineering, HR, Liasing with govt. bodies, Internal co-ordination, Customer and Vendor dealing etc.

Leading the entire Plant Team with lot of initiatives and driving in line of Professionally managed organization.

Setting up of a green field projects with complete systems & processes & running in smooth manner.

Proven hands on skills are Manufacturing Operations, Project Management,Process Engineering c GMP, IMS, Process reengineering and improvement, Basic and detailed Engineering, Technical services, Construction Management, Corporate strategy and development, Strategic planning and management, SAP Operation, All types of Audits, Operating & Capital expenses control, Statutory compliance, Continuous improvement, Technology transfer, Cost Control measures, Energy conservation, HR and IR Relationship,Material Resource Planning, Negotiation, Ordering, Procurements, Supply chain management, Forecast, Logistic, Safety etc.

Analysis of root cause during repeatative process problem and proposal for CAPA ..

Planning & implementing the Preventive & Predictive maintenance of Plant, Machines, Personnel, Equipments for improving the overall reliability, Safety & maximum efficiency under safe operating conditions.

Ensuring adherence to highest standards thru’ ISO 9000, 14000, 18000, IMS training, zero accident, monitoring and control of GPCB & CPCB, MoEF, PESO, MAH standards.

Area of expertise

Technical : Process design of all basic Chemical process equipments like Heat Exchangers, distillation columns, Dryers, Vessels, Evaporators etc., Calculations of mass & Energy balance and all type of process requirements and finally profit & loss of Plant .

Profitability: Ensuring resource optimization, Cost control, analyzing MIS & Effective Business Review .

Factory Operations & Maintenance: Ensuring quality norms, Production targets, smooth operations, Direct involvement in all Plant activities . Reviewing maintenance schedules, maintaining norms w. r. t .Pollution Control Boards.

Set-up Systems and Processes : Ensuring adherance to SOPs & Process definitions .

Liaison : Handling Expense accounting, All compliances, Liaison with Local Authority, Govt. body like excise, Pollution, Labour, Industry Deptt. etc., all negotiations.

Petroleum Processing, Petroleum Projects, Petro Chemicals processing, Fractionating column operations .

I Project Core Experiences;

Responsible for the Development and implementation of manufacturing plans, methods, and processes.

With most appropriate and cost-effective methods, processes, tools and systems.

Developing the capital expenditure budget & raises CAPEX as required.

Finalizing the selection and installation of Process equipments, machines etc.

Responsible for all aspects of Projects objectives to meet Time & Cost Deadlines, execution & Master schedule.

Coordinating with Engg. Depts. & Consultants for Design and timely availability of deliverables.

Man Budgeting & Control, Establishing Engg. Documents & Procurement and Vendor Document reviews.

Managing Site Queries & liaising for obtaining various approvals & clearances.

Reporting with MD/Technical Director on project status.

Maintaining safety norms during project concept and execution.

Providing leadership to the project team includes engineering, procurement and construction.

Oversee Change Management, Compliance with all Company’s policies, procedures and technical standards.

Completeness of the basic engineering and look for opportunities for value addition .

Development of the PFD and input to the P&ID, Detailed design of Proprietary technology, such as distillation columns, adsorption systems and heat exchangers etc .,Specifications for process and related equipment, line sizes, instruments and valves,

Applying engineering standards, procedures, guidance to engineers, trouble shooting, Work load planning.

Liaised with engineering disciplines, Hazop, Performance Review and assessment teams.

Project implemented : Petro chemical, Distillation columns, API bulk drugs, Polymers, Acrylic fibers, Distilleries, Biogas Plant, Acetaldehydes, CO2 plant, Synthetic Adhesives, Resins units, Ethyl acetate, Butyl acetate Sulphuric acid, Phosphatic fertilizer plant, DM water plant, ETP and various off sites like Alcohol storage tanks,tank farms, EPC etc.

II. Production Core Experiences:

A. Coordinating with marketing, planning and procurement functions for establishing production and delivery schedules with overall responsibility.

Preparing plant operating and revenue budgets and obtains approvals.

Ensuring that the operating costs remain within approved budgets by standardized production plan and capacity.

Preparing and submitting monthly budget, compliance reports and variance reports.

Ensuring plant Preventive maintenance schedules and optimal uptime of plant and machinery.

Monitoring plant performance on a daily basis.

Ensuring that the ERP package is constantly updated pertaining to manufacturing.

Coordinated plan and supported for new product development with the business development division.

Ensuring timely delivery of materials, routine maintenance, calibration and trouble shooting on a regular basis.

Reviewing new process and product technologies from R&D and providing the infrastructure required for scale-up and manufacturing.

Cost Management : Ensuring departmental budget for the financial year and constantly working on parameters for reduction in costs without compromising on Quality.

Resource Management : Ensuring optimum utilization of resources like manpower, equipments and materials with structured MIS system.

Developing employees on functional, technical skills/, safety etc.

Administering control measures of the resources and facilities.

Audits : Implementing the ISO, EMS and OHSAS, IMS, 5 S in all departments & approval of audit.

Documentation : Ensuring programming, planning, production and delivery with proper documentation.

Co-ordination : Reviewing inter department compliance, SOPs, equipment, Process and co ordinate GMP, ISO, QA, QC, 5 S, Stores, Accounts, Regulatory Affairs, Purchase and HR &Admin.

Safety Health Environment : Responsible for the overall EHS and compliance under the Act & all times safety.

Driving and coordinating all activities for Certification of ISO, EMS, OSHAS, IMS, 5S, c GMP and WHO etc.

B. Business Acumen : Setting-up production targets to meet time schedule, cost and quality parameters.

C. StrategicThinking & Planning : Formulating and implementing strategies for achieving annual business goals and managing overall operations of the unit. Foresee the performance bottleneck, corrective measures to lead the team to achieve organizational goals and industry best practices.

D. Statutory Compliance : Ensuring compliance with the provisions of the following statutes:

The Factory's Act,State Factory Rules and all applicable statutory rules and regulations with the Operations .ry.

Compliances of EHS regulations: Complying with state GPCB, CPCB, MoEF, PESO and Govt. bodies.

Liaison work. : Knowledge of rules for storage of materials including Explosives Rules, MAH Chemicals etc.

Knowledge of Central Excise Rules & Procedures prohibition & Excise regulation for storage of alcohol.

E. People Management : Monitoring performance of individuals on functions & behavior, and filling the gaps.

Develops procedures and policies to increase productivity, teamwork and quality focus.

F. Leadership : Ensuring qualified successors are available for key positions.

G. Customer Focus: Supporting the Marketing team for timely dispatch of the quality product.

H. Vendors: Ensuring use of quality material and approved quality vendors.

III Achievements :

Enhanced Proctivity & completed pending projects in time at budgeted cost at Prolife Industries & BEIL and brought the units in profit to expectations.

Enhanced productivity to targeted level which was pending from long years by process optimization,

specific direction at TEAMEC Chlorates Limited .

Implemented 2 nd Line of Acrylic fibers manufacturing unit consisting of 6 reactors of 50 k l each with distillation unit, spinning line etc. at M/s Pasupati Acrylone Limited Moradabad which was difficult from many years.

Savings achieved due to reduction of raw materials consumptions,utilities and power consumptions by INR 3 crores in a year by implementing Continuous Improvement Plan.

Enhanced existing Acrylic fiber plant capacity from 100 TPD to 140 TPD .

Credit to implement green field projects of Acetaldehyde, Acetic Acid, Ethyl Acetate, Butyl Acetate in 4 months time .

Implemented API Bulk drug GMP project in 6 months time with 36 reactors in M/s Surya Pharmaceuticals Limited Chandigarh .

Renovated old API Unit consisting of 34 Reactors and distillation systems in house in 4 months m/s Tata Projects / Jacob Engineering were asking 15 months time for the same rennovation.

Independently executed green field Polymer Projects of M/s Kores India Limited at Rudrapur in 8 months time and brought the unit in profitability in the very beginning years.

Raised the productivity in M/s PPCL and awarded with promotion in two years.

Played a very vital role in raising the Production of the unit and got awarded by Unit Head on regular basis .

Professional Experience

Relevant Experience : 18 Years as Unit Head on over India basis

General Manager Works : M/s UPL Group ( BEIL – Bharuch Enviro Infrastructure Limited ) Ankleshwar

Since July 2017 to Present

Unit Head with Overall responsibility of operation, maintenance & administration of hazardous industry engaged in hazardous waste management like land filling, Incinerations and MEE -multi effect evaporators and coprocesssing . DCS & PLC based operations of Incinerators & MEE. Working closely with regulatory bodies Pollution Control Board, Hazardous Chemicals & basic factory regulations .Team size 750 manpower, Group Turn over Rs. 5000 Crores .

General Manager Operations – M/s Prolife Bio Chemical Industries Pvt .ltd . Ankleshwar

Operations & Projects : Since June 2016 to June 2017 .

Over all responsibilities of Operations, P & L of manufacturing of Pharmaceutical Speciality Chemicals / Advance Speciality Intermediates for Pharma industries / Dye intermediates, Speciality high valued R & D based hazardous chemicals Manufacturing units & New projects implementations . current manufacturing DTPT, DTPT SA, BIS PHENOXY ETHANE, 1,6 ND SA, Chromotropic acid, DMPPDA, 1,3,6 NDTSA etc. Manpower 350 & Turn Over above 200 crores.

Sr. G M Operations : M /s TEAMEC Chlorates Limited (M/s Chemfab Alkalies Group ) Ongole

Operations & Projects : Membrane cell technology Jan . 2015 to May 2016

Unit Head Operations with P& L responsibility & Single point accountability of Operations of Continuous Process DCS based -- Sodium Chlorate & fine Chemicals unit at Ongole . Group Turn over INR 1000 Crores. & Group manpower 1200. ( B to B business ).

Head Chemical Division M/s Pasupati Acrylon Limited, Moradabad U.P. Since May2011 to December 2014 Functions : Continuous Polymer Unit, Head Production & Projects

Head of Chemical Division & HOD Production of 140 TPD Acrylic fiber Unit based on PLC, DCS, SCADA to Manufacture & Control Process of Continuous Polymerizations of Acrylonitrile with CSTRs, Distillation units, Acrylic Fiber Spinning unit / Dyed acrylic fiber unit (SNIA BPD Technology) . Enhanced existing Acrylic fiber plant capacity from 100 TPD to 140 TPD . Working Unit turn over INR 600 crores. Manpower 750 . ( B to B business ).

Sr. General Manager (Works ) & Unit Head API Bulk Drug Company, M/s Surya pharmaceutical ltd, Chandigarh since Feb . 2008 to April 2011 Functions : Operations & Projects

Unit Head Operations & Provided a single point accountability of Greenfield and Brown field API Projects of 7 ACCA, 7 ANCA, Cefixime, Cephalexin, Cefuroxime, Cefaclor, Menthol with GMP standards to deliver the Projects in accordance with commitments & full Project Authority, within established budget in company’s operating policies & resources. Erected & Commissioned GMP Plants with modern facilities of global standards . Guided manufacturing operations, coordinated plant activities to set up standards to achieve Organizational Objectives. Turn over INR 1400 crores & manpower 750. ( B to B business ).

General Manager ( Works ) & Unit Head M/s Kores India Ltd., Mumbai : Unit : Rudrapur Polymer Unit : Oct. 2004 To Jany20 08 Functions : Operations & Projects

Unit Head Operations with power of attorney to set up and execute green field projecs for Production of Polymers from concept to commissioning, establishing all departments and Heading Operations with P & L Responsibility to manufacture Polymers, Synthetic Resin Adhesives, Polymers of vinyl acetate, Polymers of Acrylates, paint binders and Various others . Group turn over INR 1000 crores & Unit manpower 450 . ( B to C business) .

General Manager ( Works )& Unit Head – Century Group, Vapi Gujarat : November 2000 to September 2004 Functions : Operations & Projects

Unit Head Operations with power of attorney to execute green & brown field Polymer projects & owning Manufacturing with P & L responsibility to manufacture Polymers, Synthetic Resin Adhesives, Polymers of vinyl acetate, Paint Binders, Synthetic Rubber based Adhesives and many other products similar to PIDILITE, Henkel etc.

Brought the Business from debt to profit in begininig of 6 months . The company got recognition in the market and it became leader in the field. Group Company turn over INR 1000 crores & Unit manpower 250 (B to C business).

Production Manager/ Project Head M/s Jubilant Life Science Ltd. Gajraula U. P. & Nira Pune Maharastra: May 1995 To October 2000 Functions : Operations & Projects

Single point accountability as Project Manager of Continuous process Organic Chemicals Projects with Project conceptualization, PFD development, designing, Contract finalization, Ordering, Dealing with Process Licensers, Suppliers, Site Fabricators and Contractors, Planning, scheduling, Procurement of Materials & Equipments, Construction . Up-gradation of Plants, Development and Design of New Project, Bill of materials preparations, Vendors development, Execution, commissioning & Operating of units . Group turn over INR 5000 crores & Unit manpower 750 ( B to B business) .

Plant Manager M/s PPCL New Delhi (A Govt. of India U. T ) : August 1987 to 15 th May 1995 Functions : Operations & Projects

Plant Manager with Active participation with Process Licensers GmbH Lurgi West Germany and Reputed Engineering Company M/s FEDO, PDIL, DMCC, and various others . Erected, Commissioned and Operated fertilizer plant, DM Water plant, Water treatment Units, Effluent Treatment Plant & Roaster and Acid Unit by GmbH Lurgi West Germany .After completing Erection & Commissioning taken charge of Production, Operations and Maintenance of Roaster and 350 TPD Sulphuric Acid plant, 800 TPD SSP plant as Plant Manager . Company turn over INR 500 crores & Unit manpower 750 ( B to B business).

Personal Information

Name : Om Prakash Mahto

F’ Name : Late Nathu Singh

DOB : 12.01.1961

Address : Ansal Courtyard Shastri Puram Agra U.P. 282007

Educational Qualification

B.E. (Chemical Engineering) – 1st Class passed in June 1984 from IIT Roorkee.

M. Tech (Chemical Engineering)- 1st Class passed in Dec.1985-IIT Kharagpur

Training Undergon

ISO 9000, 14000, 18000

Primavera Software of Project Managements

Safety Management & Hazardous Control in Chemical Industry NITIE, Mumbai. Certificate course

Environmental Mangement ISM Dhanbad. Certificate course

SAP/ ERP

Computer Skills

WINDOWS based application/ MS Office, SAP etc.

Strengths

Administrative skill,Team work, Personal integrity, Proactive to drive business agenda, Ability to challenge status quo. Excellent communication with written and verbal, Dedicated analytical ability, Honesty, Self confidence, Achievement oriented, Problem solving, Coordination and analysis, Ability to motivate people,

Present cash in hand : 21 Lacs / Anum.

Expected Salary : 25 to 30 Lacs per annum.

Notice Period : One month

Current Location : Ankleshwar

Preferred location : Any where in INDIA Reason for Change : Better prospects .

Total Experience 30 + years

Above in formations are true to the best of my knowledge.

(Om Prakash Mahto )

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