Power Plant Manager

Sarva Kuppusamy Subramanian

Mobile: 62-811*******

E-Mail: ac97ya@r.postjobfree.com

An expert in engineering industry with multi level expertise in production and process technology, multi million USD investment green field projects, Corporate governance of multi location, multi product group of companies and steel plants with corporate PL responsibility including HRD, PPC, QC, Production, Maintenance, IT dept and Data management, SQC, Marketing, Finance and accounting. Marketing of the products, market, product & process development as per the needs of the market. Procurement of Raw material and consumables as required from various well known sources.

PROFESSIONAL PROFILE

Engineering professional with over 39 years of extensive experience in the key areas of CARBON STEEL & STAINLESS STEEL TECHNOLOGICAL PLANTS Operation & Maintenance, Plant and department formations, QC, R&D, Marketing and Market, Product & Process development in various countries.

Previously Director-PT.Surabaya Steel Investama to set up the complete Cold rolling mill complex 400,000Tons/Year and its associated facilities and Director of PT.Sinar Surya Anugerah Investama, a Galvalume manufacturing plant with a CRM project. Director of PT.Dynasti Baja Makmur to set up a Hot rolling mill(1900mm wide) of 1.5 million ton.Director PT.Wijaya Baja to setup 132,000T/Yr Shape rolling mill.

Maintaining and augmenting the assets of the group and increasing and achieving the EBIDTA of the individual and group together and servicing the bank loans as healthy as possible and achieving production and marketing goals set after due diligent discussion with Share holders.

Analyzing and acquiring running manufacturing units, implementing new technology, dismantling& re erection of equipment in different countries.

Recorded success in improving plant efficiency, productivity and safety using available resources as well as implementing new methods and systems.

Familiar with the International Codes & Standards like ASTM, JIS, ASME, DIN, ISO and SNI.

Dexterous in preparing and updating procedures & methods for critical jobs & risk assessment & audit activities.

Proficient in understanding and coordinating client’s needs / enhancements, customization of product accordingly and consulting with technical team for providing solutions in adherence to delivery schedules.

Expertise in Quality control, market study, plant viability and risk management.

Demonstrated competency in providing technical leadership to the team, resolving the bottle neck, through time to time SWOT analysis.

Encouraged team work for strong problem solving skills, known to take confident decisions based on extensive experience and technical skill enables effective solutions that positively impact customer satisfaction and operational costs.

Expertized in making coin blanks using Stainless steel for India and Indonesia mints with best quality blanks.

PROFESSIONAL QUALIFICATION

Bachelor of Engineering (Mechanical) from University of Madurai India in the year 1978.

Master in Business administration from Annamalai university, India in the year 1989.

Certificate in Computer programming from Madurai University, India in the year 1987 & all MS OS.

Professional Training Attended

Hitachi, Japan on Operation & maintenance of 6 Hi cold rolling mill

Schuler Press, Germany on O&M of Blanking press for coil blanking line

Spaleck Pickling line, France for pickling of coin blanks.

BAK,Germany and Ebner, Austria for Annealing of steel & stainless steel

Usinor,France for stainless steel cold rolling technology.

Royal mint,UK for coin blanking and coin printing technology.

Ebner, Voest Alpine, Austria on Heat treatment and annealing furnaces

Various management courses, technical seminars around the world.

Computer Skills

Well versed with MS Office & Internet Applications & SAP.

CORE COMPETENCIES

Top Management

Heading the business of multi product, multi location with P&L responsibilities. Improved EBITDA, Better Labour and staff relationship, Better ESR programmes, expertise in handling multi national expatriates.

Projects and technological improvement

Project analysis, Finance requirement, land selection, technology selection and implementation of the project in time. Prepare feasibility study, Bank negotiation to get finance and documentation to get Supplier credit etc.

Executing Manufacturing, process control, Quality control, Production planning and controls, marketing and product & Process optimizing.

Environment, Health and safety procedure making and implementation ensuring safety standards and procedures are implemented and followed in accordance with contract requirements by making company guidelines.

Directing and controlling all plant activities concerned with operation and maintenance and automation equipment.

Setting up targets, KRAs, HR activities, training, and improvement of skill of personnel thus developing strong team of professional to operate the company.

Very recently bought a used BOPP Celier machine, re erected and commissioned. Also a new Rigid PVC film plant.

Installation & Commissioning / Testing

Handling erection, commissioning, inspection tests of all technological equipment to ensure completion of projects within stipulated time/ cost parameters for determining the effectiveness of equipments/ plants.

Providing technical inputs & developing master specifications with needs assessment.

Managing erection/ commissioning of process control equipments for smooth operations.

Operations & Maintenance

Planning and effecting preventive / predictive maintenance schedules of equipment to increase machine up time/ reliability.

Identifying areas of obstruction/ breakdowns and taking steps to rectify the electrical equipments & plant machineries through application of trouble shooting tools.

Preparing maintenance schedules, by implementing modern maintenance System to ensure the performance capacity of various process control equipments.

Ensuring the availability of equipment, spare parts, manpower to perform maintenance activities & shutdown activities.

Process Enhancement & Cost Saving Initiatives

Identifying areas of improvement and recommending process modifications and equipment calibrations to enhance operational efficiencies of the systems. Implement TPM.

Reviewing the operational practices, identify the areas of obstruction/ quality failures and work on system and process changes for qualitative improvement/ energy conservation through energy audits.

Preparation and analysis of MIS and various other reports to apprise share holders/top management of the routine plant operations and assist in critical decision-making.

CAREER HIGHLIGHTS

July 2018- Till now President Director – PT Essar Indonesia, Bekasi, Indonesia

PT Essar Indonesia is a Cold rolling cum Galvanizing steel Plant producing 400,000T/yr of CR sheets and coils and Galvanizing products of 150,000 Tons per year supplying whole of Indonesia and export to various countries. Subsidiary of well know big industrial conglomerate Essar India Limited.

Heading successfully the SBU with complete authority and responsibility with a turnover of300 Million USD a year with an EBITDA of around 20 million USD, unit is continuously progressing well due to strategic purchase of raw material and best sales strategy.Implemented lean manufacturing, 5S programmes along with ISO 9001,ISO 14000 and ISO 18000. Work force more than 850.

Sept 2011- June 2018 Group Director – Surabaya Steel Investama, Gresik, Indonesia

PT Surabaya Steel Investama is a new Project of Steel Cold rolling mill complex planned to produce 250,000T/yr of CR sheets and coils. Implementing the project with least cost and guiding the team with the leadership to implement strict quality controlled products for the Indonesian and export markets. Technological supplier selection, financial and feasibility analysis as well as Risk analysis to ensure a complete plant for continued operation, marketing of products.

Feasibility study and market analysis report was prepared and submitted within 4 months. Technological equipment are ordered during this period thus minimizing the project duration. Project completion expected in July 2018. Galvanizing / Galvalume line project work started and equipment ordering going on with Building work started parallel. Hot rolling mill project is under progress and financing being arranged. Hot rolling plant for shapes with a capacity of 132,000TPA is being installed.

May 2011 August 2011 Vice President – Adler steel Limited, Toronto, Canada

Adler steel Limited is an international trading company specialized in steel semi finished and finished products. A 50 million USD/yr turnover company supplying steel products from various countries to Canadian, US and South American countries.

Leading a team of 3 Managers, self could get orders up to 200,000USD of stainless steel products through implementing various negotiation skills in just 60 days.

July’06 April 2011 Vice President – Jindal stainless Indonesia, Gresik, Indonesia

PT Jindal stainless Indonesia produces 120,000 TPY of Cold rolled stainless steel coils and sheets. Providing the leadership to implement strict quality controlled products for the Indonesian and export markets by reviewing the procedures of various department functioning in the plant. Appraised the plant under PT.Maspion and key person in taking over the plant management.

Improved the production per month from 1000T to 7000 T without changing or increasing the manpower through implementation of systems and procedures.

Reviewed quality assurance & inspection procedure, site operation& maintenance procedure and improved the plant availability and enhanced the quality of the products.

Concepted and implemented major upgrades, rebuilds and new installations to double the production.

Co-ordinate with local and central government agencies to manage man power, to follow the regulations and to pay the tax etc dues regularly and get import and other tax benefits.

Conducted and implemented energy audit optimizing Electrical and Automation systems results in 20% saving in energy.

Improvement in maintenance procedures and practices thus reducing downtime by 30%.

Increased the various production machine speed to improve productivity.

Significantly contributed in saving energy by boosting the morale of the people to be involved in team activity to save energy.

Training and development of local staff in towards knowledge and understanding of modern operation and maintenance practices.

Implemented SAP system to have good control over the cost, quality and timely delivery.

Sept ’03– Jun’06 CEO Alnoor CRM limited, Chittagong, Bangladesh.

This was a new Cold rolling mill project to produce 120,000T/Year of cold rolled and galvanized products under the Alnoor group which have several Oil refineries, sugar plants, shipping and galvanised sheet units.

Headed the project activities to implement Green field project using used Cold rolling mill equipment from Cold Spring, Hamilton, Canada.

Balancing equipment was designed, technological supports were got from specialized suppliers and the whole project was implemented without any fall back situation.

Actively involved in obtaining ISO certifications for quality, safety & environment.

Implemented SAP and other material management software to improve the control over the cost.

Involved in project feasibility analysis and obtaining investment fund from Banks.

Introduced PC based maintenance planning & management.

Successfully implemented condition monitoring system.

Implemented new products like Cycle Ricksaw steel project which is the maximum used vehicle in Bangladesh thus increasing the market share.

Responsible to manage all the units under the group totaling USD 400 million turnover and assets over 200 million USD.

Nove’95– August’03 General Manager, PT.Essar Dhananjaya, Cibitung, Jakarta

PT.Essar Dhananjaya is a Cold rolled steel complex producing 200,000T/Year Cold rolled steel of various grade under the umbrella Essar Group, India.

In charge of operation of 2.2 million tons/year Hot rolling mill in Hazira plant, India

To implement Cold rolling mill in Indonesia, special appointed project manager for Project implementation, Technological equipment selection, erection and commissioning all equipment to ensure smooth operation of the entire unit in Indonesia

Implemented new business model suitable for Indonesian market- like business model in USD only thus avoiding the risk of currency exchange variation.

This model saved the plant from catastrophic devaluation/failure of Indonesian currency in 1998.

Added new machineries thus entering into Galvanizing market and enhancing the total capacity to 400,000T/year.

Developed various products for automobile sector, Drum making, Enamelware, Electrical transformers etc.

May’79–Oct’95 Asst General Manager, Salem steel Plant, Salem India

Salem steel plant is a part of SAIL(Steel authority of India) a public sector steel plant specialized in Production of stainless steel in India for the first time. Self was the team member to bring the know how from France to India.

Erection and commissioning of various plant units of Cold rolling mill and Hot rolling mill.

Implemented all department systems to ensure smooth take over of the plants from supplier and operate them efficiently for the first time in India.

Made feedback procedures to improve the quality of new products and also enhancing the efficiency and reliability of various equipment.

Special in charge of erection and commissioning of Hot rolling mill for stainless steel incl walking beam furnace.

Special in charge for erection and commissioning and operation of Stainless steel Coin blanking line.

First person in India to be in charge of making coin blanks and trained in Royal Mint Cardiff, England as well as Blanking press,annealing and pickling of coin blanks and polishing.

June’78– Apr’79 Asst. Plant Manager, Turbines 100MW. Neyveli Lignite corporation, India

Salem steel plant Neyveli Lignite corporation is a public sector undertaking to produce electric power from Thermal power plants using Lignite, a low quality coal available in plenty.

Operation and maintenance of 100MW power plant turbine division.

In 4 months time, complete Competency examination for Power plant engineer certificate to operate boiler, thus promoted as Plant manager for Boiler operations.

PERSONAL DETAILS

Date of Birth : 08th April 1955

Languages : Tamil, Hindi, English, Malay, French & Bahasa Indonesia

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