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Manager Maintenance

Visakhapatnam, Andhra Pradesh, India
May 11, 2019

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Skype ID:n_nehru1


~ Strategic Planning ~ Manufacturing Operations ~ Production~

Across Steel Industry, Steel Melting Shop, Slab Caster, Billet caster, Rolling Mills & refrigerating Industry

Academic Credentials

B.Tech Mechanical Engineering from Kakatiya University, Warangal, in 1987

IT Skills

Attended Computer Aided Maintenance Management System (CAMMS), AutoCAD, Office Automation & Internet Applications,Lotus Notes,Sap Material Management system,PM Module

Personal Snippets

Date of Birth: 12th July 1965

Languages Known

Hindi, English, Telugu & Oriya

Present Address:

Electrosteel Steels Ltd, Bokaro.

Permanent Address:

H.No: MIG-I/125, Gullalapalem Colony,Sriharipuram,Visakhapatnam - 530011, Andhra Pradesh

Passport no:R7198455,

Date of Issue of passport:17-11-2017,

Date of expiry of passport:16-11-2027

Professional Synopsis

Mechanical Engineer with around 28 years of rich experience in plant projects & maintenance. Areas of expertise involve

Successfully handled numerous erection & commissioning projects. Keen understanding of the implementation & documentation formalities for ISO/ TPM Systems.

Proficient in handling production operations and accountable for quality service & timely completion of the projects.

Steered the entire project from the Greenfield stage of the site project work to civil work, mechanical fabrications & erection, erection and commissioning of equipments, sponge iron production as well as plant administration.

Instrumental in adhering to key performance indicators of International standard like OPE, OEE, Maintenance cost per ton of steel production, Project cost per ton of Installation, MTBF and MTTR, to ensure operational excellence.

Hands-on experience in the field of Steel Production, Sponge Iron Unit and Integrated Steel Plant Project -in Selection of Technology, Designing, and Coordination at all level from consultant end to execution level.

Instrumental in planning & implementing the preventive & predictive maintenance schedules for improving the overall reliability and safety of plant, personnel and production processes. Implementing preventive maintenance programmers to improve the efficiency of the system or the equipment undergoing maintenance.

Talent for proactively identifying and resolving problems, ramping up project activities with on time deliverables and maximizing productivity.

Astute leader with ability to lead teams towards optimizing their performance levels. Excellent planning, organizational and interpersonal skills.

Resourcefully formulated & implemented various sanction schemes for improving plant efficiency, reliability and maximum utilization of available resources. An effective communicator & team leader.

Technical Know-How

Hot Strip Mill Mechanical Maintenance of Capacity 2MT

Basic Oxygen Furnace of capacity 150T,Mixer of Capacity 1300T In Steel Melting Shop,

Slab caster of capacity 2MT,Ladle heating Furnace

Electrical arc Furnace of capacity 110 T,

Billet Caster of capacity 1MT,

Wire Rod Mill, Light Section Mill

All Belt Conveyors: 800 TPH to 1200 TPH Capacity

Water system, waste water treatment

BF gas, Coke Oven gas, Natural Gas, CO gas pipe lines Maintenance,

Gas cleaning Plant & Gas Recovery plants of BOF, Fume extraction systems of EAF and LF

Centralized Grease Lubrication Systems

Hydraulic Systems for the equipments

Condition Monitoring of Equipments

All pneumatic systems and all other utility pipelines, Waste Heat recovery boilers.

EOT Cranes

Reciprocating Compressors

Refrigerating Industry

Rice Mills

Functional Expertise

Strategic Planning: Formulating Annual Operating Plan and strategic action plans to achieve the set objectives; streamlining existing processes to enhance efficiencies while minimizing operational time / costs.

Project Management: Overseeing project activities from conceptualization to execution including finalization of DPR, technical specifications, procurement / supply of raw materials, stage inspections, scheduling, progress monitoring, site management and manpower planning.

Production Management: Developing & implementing SOPs / quality systems; conducting regular internal audits and reviews to ensure adherence to pre-set norms. Leading the implementation of quality assurance in raw materials, work in progress, finished goods across various functional departments.

Maintenance Management: Planning & implementing the preventive & predictive maintenance schedules for improving the overall reliability and safety of plant equipments & machinery. Conducting failure investigation analysis to identify gaps & take corrective measures so as to reduce equipment downtime & maximize plant availability.

Team Management: Establishing the team for all departments and providing direction, motivation & training to the team for ensuring optimum performance.

Experience Chronology

U & I Infrastructure India Private Limited, Hyderabad( since may’ 15 to till now)

Noteworthy Highlights

Founder of the above infrastructure company and one of the directors

Overseeing project activities from conceptualization to execution including finalization of DPR, technical specifications, procurement / supply of raw materials, stage inspections, scheduling, progress monitoring, site management and manpower planning.

Erection and commissioning of all the activities of the project

Controlling the cost of construction of buildings and making the organization profitable.

Marketing the plots and apartments.

Electrosteel Steels Limited, Bokaro (since oct’12 to april’15)

Noteworthy Highlights

Led operations and Mechanical maintenance of SMS for the 2.2MT steel plant.

Closely monitored and completed all the erection and commissioning jobs of SMS.

Holds the distinction of being the Project leader of SMS, capacity of plant is 2.2MT steel with Basic Oxygen Furnace route and Billet caster(125mm and 150mm Billets)

Spearheaded all project management activities.

Hot commissioned SMS successfully with zero maintenance delay.

Implemented ISO in shortest duration. Instrumental in making checklist, SOP and SMP of equipments (3 months from date of declaration of implementing ISO)

Planned successfully for procuring spares / consumables for running the plant without any data by OEM / Contractor (i.e Data was not provided by our Principle contractor SDM, China )

Implementing/ monitoring of KRA of 35 engineers in our section by dividing SMS into 7 individual areas(Basic Oxygen Furnace, Caster, Bulk Material Charging System, Gas Cleaning plant with Waste Heat recovery Boiler, cranes, Utilities and All Hydraulic,pneumatic and centralized grease and oil lubricating systems in the shortest possible time.

Preparation and implementation of annual maintenance plans and maintenance budgets for SMS

Reduced Operation & maintenance cost by reducing consumption of LPG, Hydraulic oil, Oxygen and Nitrogen gases.

Improved MTBF of critical equipments like ID fan of GCP, Oxygen lance drive of converter.

Controlling the maintenance cost of 2$ per ton of steel production.

Delta Steel Co. Ltd, Aladja-Ovwian, Warri, Delta State, Nigeria ( Feb'2008 to Sep’2012)

Assistant General Manager/ Head of mechanical Maintenance in Steel Melting shop (1MT per Year)

Noteworthy Highlights

Spearheaded Mechanical Maintenance for Electric arc Furnaces, Ladle Heating Furnace & Billet casters (100 mm and 120mm Billets).

Led the gamut of activities as Head of Mechanical Maintenance in SMS leading a group of 150 technical staff including Indian and Nigerian staff.

Successfully planned & controlled operations for preventive & breakdown maintenance of all Mechanical equipments of SMS.

Rendered the Expatriate Training to Nigerian employees about preventive maintenance activities, Annual Maintenance Plans, Spares planning, Route cause analysis, Failure based trainings, etc.

Instrumental in preparing, implementing & training the Workers regarding the OPE, Kaizens, SMP and SOP of equipments.

Involved in the implementation of Six sigma projects based on the Previous equipment failures/Reducing the MTTR and Increasing the MTBF.

Chaired the PM pillar in TPM methodology in SMS and implementing the all activities of PM pillar in SMS.

Prepared monthly performance report & MIS and providing the same to the management for facilitating decision making.

Ajaokuta Steel Co Ltd., Ajaokuta, Kogi State, Nigeria (June 2005 to Feb'2008)

Senior Manager in Rolling Mills consisting of Light Section Mill and Wire Rod Mill

Noteworthy Highlights

Stellar role in leading operations as Head of Mechanical Maintenance for Both the rolling Mills and leading a group of 200 technical staff including Indian, Ukranian and Nigerian staff.

Involved in training the Nigerian employees about preventive maintenance activities, discipline, work culture, technical know-how and TPM activities; worked in close coordination with other (Ukraine) expatriate to achieve goals.

Actively participated in the Six Sigma Projects and effectively carried modifications in Cassette Block, Pinch Rolls, Ejector Ram, Vertical Stand Screw down mechanism and Cooling Bed Lifting Device assembly.

Led to reduction in the breakdowns/ increase availability of Equipments and thus increasing production.

Steel Authority of India Ltd, Rourkela Steel Plant, Rourkela (Aug'1992 to May 2005)

Manager in SMS and Hot strip Mill from Junior Manager to Manager (Mechanical Maintenance)

Noteworthy Highlights

Played pivotal role in erection & commissioning of jobs of Basic Oxygen Furnace Shop, Mixer, Gas Cleaning Plant, Gas Recovery Unit & Continuous Slab Casting Machine, Ladle Heating Furnace, Pump Houses, Hydraulic Systems, Lubrication Systems and all Utility Pipe Lines.

Coordinated with Suppliers & Erection Contractors M/S TPE, Russia, MDH, Germany, Mukund and Mecon for all SMS Equipments and involved in preventive and breakdown maintenance of all the SMS equipments after commissioning and bringing the plant to rated capacity of 1.44MT per year.

Successfully implemented the CMMS (Computer managed maintenance System and IMMS (Integrated material Management system) modules successfully in SMS.

Significantly contributed as:

•Head of Mechanical Maintenance for all equipments in Slab Caster Including Ladle Heating Furnace.

•Shift In charge (Mechanical Maintenance) in Hot strip mill (1.5MT per year) and involved in Preventive maintenance and Breakdown Maintenance of equipments.

Effectively carried out the cost control of Hydraulic Oil in SMS by reducing the cost by 70%

Closely monitored the condition of equipments like Vibration analysis and Static Balancing of all ID Fans. Lube sample analysis.

Successfully completed training on Reliability Centered Maintenance from Centre for Power and Training Institute, Rourkela

Undergone training on Advanced Hydraulics by Rexroth, Ahmadabad

Preceding Assignments Handled

March 1990 to July 1992 Hyderabad Allwyn Limited, Hyderabad, Andhra Pradesh Junior Manager

May 1987 to Feb' 1990 Panduranaga Rice Mill, Hanuman Junction, Andhra Pradesh Junior Manager

References & documentation shall be furnished as & when required.

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