Project Management Strategic Planning
Resume:
R S KULKARNI *.*.********@*******.***
**************@*****.***
SENIOR MANAGEMENT PROFESSIONAL- Over 3 Decades of Experience Strategic Planning & Leadership Project Management Erection & Commissioning Operations & Maintenance of Iron Making Units like Blast Furnaces /Corex.
Expertise in championing organization values & vision and overcoming challenges with hands-on experience in instituting Executive Profile
Excellence in streamlining operations & maintenance, commissioning, and developing & implementing new systems within the plant Rich experience of working on India’s largest Blast Furnaces (2 nos.) 4018 cubic meter and Blast Furnaces 1 & 2, Corex 1 & 2 Experience in maintenance schedule planning, budgets formulation, annual planning, troubleshooting, manpower planning and risk assessment analysis
Rich project management experience with expertise in developing project baselines, monitoring & controlling projects with respect to cost, resource deployment, & quality compliance to ensure satisfactory execution Innovation-focused with success in managing erection, testing & commissioning and enhancing operational effectiveness of Blast Furnaces Highly skilled in managing site operations, quality service and timely completion of projects along with testing and commissioning of various plants
Strategized techniques for maximum utilization of manpower with thorough understanding of industry & technology trends; implemented manufacturing techniques & methodologies to achieve product excellence Successfully managed technical, financial and administrative issues; ensured adherence to safety, environment, regulatory and energy conservation norms
Excellent at establishing relationships with govt. departments, and acquiring govt. permits & clearances for successful execution of projects Expertise in implementing cost saving techniques/measures and modifications to achieve reduction in all types of O&M expenditures Skills
Skill set
Key Impact Areas
Project Planning & Management
Operations & Maintenance Planning
Decision-making Support /Process
Enhancement
Strategic Planning & Leadership
Erection/ Commissioning
Budgeting/ Forecasting/ Cost Control
HSE/ Regulatory/ Compliances
Spares Management/ Procurement
Profit Centre Operations
Commercial Operations
Team Building & Training
Soft Skills
Communicator
Multi-cultural
Collaborator
Project management
Strategic planning
Contracts and commercial
P&L management
Business Development
Cost control & budgeting
Regulatory systems
Asset management
Revenue generation
Commissioning & take overs
Power system management
Education & Credentials
BE in Mechanical Engineering from Vijayanagar Institute of Technology in 1987 with 65%
Career Timeline (Recent 5)
Uttam Galva Metallics
LTD as Head of Projects
and Maintenance
J- Tech
Engineers as
Director
Ashok Iron Works
Pvt Ltd As Senior
VP
JSW Steel LTD
as Head Of Iron
Making
2006-2008 2008-2019 2019-2020 2020-2021 Present
Suzlon Energy LTD
Head Projects and
Maintenance/ OP
Selected Highlights & Contributions
Merit of successfully:
o Revamping of 4018 cub metre furnace bell less top equipment within record time of 48 hours o Hot repair of hot blast main with the help of in-house resources within short span of 72 hours o Executing rebuild/repair of stoves within 6 months of record time (Danieli Corus design) Steered:
o Modifications in all de-dusting systems to ensure chimney dust emission parameter within stipulated limit of 10gm/NM3
o Modifications in water systems to maintain specific water consumption of .6m3/THM Implemented:
o 5S housekeeping practices and mapping of 5S activities o Speed, agility and innovation mantra across/within the team o TQM tools like 7QC tools to prepare for Deming award and grand Deming award o 0757 as the JSW TQM Mantra
Drove erection of coke drying projects to bring down the coke moisture by 3% from 8% (thereby achieving low hot metal production cost)
Commissioned in-house developed platform in Paul Wurth Bell less top to use while replacement of upper seal valve for which earlier it was consuming around 120 T of coke and incurring cost of INR 20 lacs as waste Built special tools to replace 36 nos. of blowpipes within 12 hours and replacement of BLT distribution chute within 8 hours
Delivered Fast Distribution Valve in cold blast line to save shut down of the blast furnace in case of power failure Ensured LTIFR .24 by following all the 10 safety standards on a daily basis Conceptualized strategy & achieved 3 million man-hours in safety in each furnace and ensured zero fatal accidents Worked as Chairman of Departmental Safety Committee; conducted monthly contractors safety meeting Administered erection and commissioning of Top Recovery Turbine to produce 9 mw power/day Conducted modification in drives to maintain the specific power consumption of 145kwh/THM Played a key role in getting most precious TQM Award of Deming Managed maintenance of subunits like Reduction Shaft, Melter Gasifier, Hot Metal / Raw Material Handling Systems, Coal Drying Plant
Successfully managed erection & commissioning activities of Corex C-2000 Module 1 Furnace in Oct 2000, Corex c2000 Module 2 in Apr 2002, 1250 Cubic Meter Blast Furnace in Aug 2004, 1650 Cubic Meter Blast Furnace in 2007 and 4018 Cubic Meter Blast Furnaces 2 nos.- one in Feb 2008 and second one in 2011 (one of the biggest Blast Furnaces in India)
Involved in erection and commissioning of Coal Grinding Mill for Pulverised Coal Injection/Revamping of 4018 Cubic Meter Blast Furnace BLT System within 24 hrs
Attained:
o 8% reduction in downtime through effective maintenance practices like condition monitoring, thickness monitoring, utilization of opportunity maintenance
o 0.2% escalation in OEE & plant productivity due to major modifications like 10% of oxygen enrichment and 200 KG/TPH of coal fines injection through tuyers
o ISO 9002 and ISO 14001 for the organization; maintained consistency in ISO related documents Bagged:
o Certificate for excellence in performance improvement projects o Cash Award for best performance
Revived Chilled Melter Gasifier jammed DRI Screws and emptied reduction shaft within 48 hours and achieved high melting rate of 120 T/hour
Drove the implementation of indigenization / interchangeability of spares, adoption of CMMS to ensure availability of spares at any given point of time; reduced maintenance cost per ton of hot metal from INR 165 to INR 135 Delivered training programs like Hydraulics Training by Vickers India Ltd., Managerial Training Program by Kirloskar Technical Institute, Harier Karnataka for all employees in the dept. Kirloskar Erected & commissioned two 250-m3 Blast Furnaces in 1995 and 1996 Organized training programs like Bearing Assemblies, importance of Lubrication System in Steel industry Planned & led erection & commissioning of 4018 cub meter Blast Furnaces 2 nos/, 1250 cub meter & 1650 cub meter Blast Furnaces, Corex C 2000 Furnaces 2 nos., 3 Coal Grinding Mills and so on As a cross functional team member involved in executing capital repair (9 days) of 3 million tonne Pellet Plant Monitored MTTR & MTBF of equipment; ensured equipment availability and furnace availability of 98% Proved:
o Seventh ranking benchmark for world steel association o Coal fines injection of 200 kg/THM
o Ensured 100% availability of SGP system
Organizational Experience
Since 4th October 2021 is Director At J Tech Engineers and Fabricators Belgaum. Since May 4th To 28th Setpember 2021 working as Head Projects and Maintenance At Uttam Galva Metallics Ltd August 2019 to 2021, Ashok Iron works Ltd Belgaum Karnataka, 590001 as Senior Vice President (operations) handling all the three plants and foundry Units. July 2008 till Jan 2019: JSW Steel Ltd., Bellary, Karnataka, India as Head of Iron Making 5 MT & 7 MT (4018 cubic meter Blast Furnace 2N0S, COREX C 2000 Furnaces 2 Nos,2350 cub mtr one furnace and 1650 cub mtr one furnace) Role:
Erection and commissioning of blast furnace 3&4 0f 4018cub mtr capacity each since grass route level including site preparation & equipment selection
Heading operations and maintenance of Iron making 5 Million tonne and 7 Million tonne Furnaces
Working out various requirements, monitoring overall project operations and ensuring timely completion; setting up standards, ensuring optimum utilization of available resources to achieve organizational objectives
Monitoring the activity at sites and project schedule, ensuring cost control within the budget and plans
Planning erection, testing & commissioning as well as preventive & predictive maintenance schedule for the plant
Adhering to safety, environment, regulatory norms
Leading, mentoring & monitoring the performance of team to ensure efficiency in process
Implementing & maintaining all the activities in area of generation, maintenance & new facility planning; ensuring plant availability, reliability and generation as per the annual operating plans
Troubleshooting and driving preventive / breakdown / shutdown maintenance of rotary / static equipment, to reduce downtime to minimum
Involved in site functions including execution activities involving laying foundations, installation of furnace shells, compressors, pumps, ID & FD Fans, hydraulic power packs, steel structures, piping
Managing commissioning of electrical substation, high and medium equipment, generators, civil works, erection & testing of equipment, commissioning of the plants
Previous Experience
July 2006 – July 2008: Suzlon Energy Ltd Coimbatore (SE Forge LTD foundry) as Head (Projects/Operations and Maintenance)
As a Project head of biggest gray iron foundry in the country Major responsibilities
Total involvement in plant procurement & lay out finalization of 40000T capacity castings and forgings.
Actively participated and finalized plant layout
Charging cranes and systems erection and commission
Mould shop with various pits and risers for pressurised mouldings so as to avoid cavity and blow holes in the castings
Sand preparation units with various equipment and hematite/magnetite material addition so as to have proper bonding of the core
Core shop equipment erection/commissioning
Installation of heat treatment bay with top hat annealing furnaces
Fettling section with automatic swing frame grinders with hydraulic systems
Dedusting systems with dedicated compressors
Painting bay with computerised programmed painting of castings.
Actively involved in technical discussions of procurement of all foundry equipment like 8nos of 8T capacity induction furnaces with robust cooling systems with level 2 automation
Planning of basic raw material to start the foundry.
Recruitment of maintenance /operation team to run the foundry
Setting up of full-fledged maintenance systems with SOPs and SMPs
Quality circles/kaizens/OPL/5S implementation
December 1996 – July 2006: JSW Steel Ltd., Bellary, Karnataka, India as Assistant General Manager. Major responsibilities
Involved in erection and commissioning of two nos of grass root projects COREX 1&2 including procurement of various indigenous and international. Setting up of maintenance dept.
Undergone Management training at POSCO STEEL PLANT POHANG, South Korea to operate & maintain the COREX plants
Erection and commissioning of 1250 cub mtr blast furnace since grass root level and maintenance of the same
Erection and commissioning of 1650 cub mtr blast furnace 2 since grass root level and maintenance of the same. October 1994 – December 1996: Kirloskar Ferrous Industries Ltd., location as Senior Engineer Major responsibilities
Erection and commissioning oh 150 cub mtr 2nos of mini blast furnaces since grass root level
Maintenance of 2nos of blast furnace including setting up of full-fledged maintenance department. June 1992 – October 1994: Sessa Goa Ltd., India as Maintenance Engineer Major responsibilities
Erection and commissioning of 2nos of TATA KORF technology mini blast furnaces since grass root level including equipment procurement
Setting up of maintenance department including recruitment of maintenance team
Formation of SOP& SMPS /Spares planning.
October 1989 – June 1992: Deccan Cements Ltd., India as Junior Engineer Major responsibilities
As a front-line engineer handled responsibilities of maintenance and operations of packing section/Kilns/Cement mills and raw mills.
October 1988 – October 1989: ACC Babcock Ltd. as Management Trainee Major responsibilities
As a management trainee handled responsibility of foundry maintenance including manufacturing of cement industry crusher hammers/induction furnace maintenance/fettling section equipment maintenance etc. including tube shop maintenance to manufacture boiler tubes. Trainings
1-month Middle Management Program from Kirloskar Institute of Advanced Management Studies, Harier Karnataka, India in 1995
Computer Orientation Program by Belhos Infotech Pvt., Ltd., Karnataka, India 1997
Extensive training in O & M of Corex Plant at Pohang Iron & Steel Co., Ltd., Pohang, South Korea in 1998
Senior Management Training program in JFE Korasaki Steel Plant, Japan for 2 weeks (2013-2014)
3-month Intensive In-plant Training Program conducted by JVSL and complete operations & maintenance knowledge about all SBUs like Pellet Plant, Sinter Plant, Coke oven, BOF/CCP, HSM, HRD, logistics, raw material handling system, lime plant, oxygen plant, power plant, transport and security
Positive Leadership Programmes conducted by Harvard University Faculty Date Languages Permanent Expected Personal of Birth: CTC: Known: Address: 1st negotiable. June Details English, 410 1965 Sanika Hindi, Landmark marathi, kannada, B Wing 9th telegu Cross and Bhagyanagar, tamil (can Angol, understand) Belgaum-590006
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