Quality Control Operations Management

Sanjeev Sharma

Specialist-Plant Operation Excellence

E-mail: *****************@*****.***

Phone:91-989******* E mail: *****************@**********.***

Soft Skills

Career Summary

Six Sigma Green Belt professional with nearly 24 years’ experience in maintenance operations management across manufacturing industries

Spearheaded entire plant maintenance operations to maintain continuity and match organizational goals through supervising operations management, quality control, process improvements, safety guidelines, new policy/procedure development.

Plan and execution of Projects/Capex related to safety, Infra, capacity enhancement, Modification, Power & Fuel reduction.

Excellence in understanding of process requirements; expertise in Plant Automation and integrating Field Instruments in DCS Network

Hands-on experience in implementing Process systems and documentation : ISO (9000, 14000, OHSAS), TRACC Modules and so on

Skilled in identifying gaps in the process and implementing ways to close gaps by troubleshooting and applying Engineering controls for process improvement, safety management, cost assessment.

Skilled in execution of maintenance work cycle involving planning,, scheduling Preventive and Predictive and coordinating all maintenance work orders of Engineering functions.

MEP services (Electrical, Air – Conditioning, Fire Fighting, Fire Detection,

Plumbing, CCTV etc.)

Proven success in cost reduction through manpower planning & optimization, power & Fuel reduction, resource / asset optimization, development of low cost vendors and improvement of team efficiency

Core Competencies

Instrumentation Engineering

& Factory Automation

Projects Planning and

Execution

Asset care, Equipment reliability

& Plant Maintenance

Process Excellence(Six sigma)

Robotics and IOT, Warehouse Automation

Vendor Development & Negotiations

Manpower Management

ISO Documentation

Strategic Planning & Leadership

Erection/commissioning of DCS (Invensys & ABB make)

Budgeting and cost Reduction Initiatives

Statutory Compliance & Laisoning

Career Timeline(Recent 4)

Organisational Experience

Since Nov-2021 with M/s Uflex Ltd., NOIDA

Since Nov’21 as DGM –Engineering & Projects (Chemical Division)

Projects in India and Abroad

Since Feb’08 with M/s Asian Paints Ltd., Ankleshwar, Gujarat

Deputations

Feb’08 to Dec’16 as Manager-Engineering (Phthalic Division)

Since Dec’16 as Manager-Engineering (Paints Division)

Key Result Areas:

Spearheaded Plant Automation, integrated various Equipments and critical parameters for monitoring and tracking in DCS in Network domain (ABB DCS ), Plant and control net on Proffibus and Optical Fibre technologies.

Planning & Strategizing for eliminating chronic issues by process improvements, Automation, achieving zero breakdowns, zero safety accident & property damage.

Implementing Instrumentation Excellence program, resolution of issues through Instrumentation and Automation

Projects: Driving erection & commissioning of various mechanical equipment & machinery to facilitate smooth project progress; conducting inspection tests for effectiveness of equipment, integrating with DCS for Auto operation.

Undertaking scheduling of preventive maintenance and Predictive maintenance of Prime Production Equipment such as Reactors, Sand mills, Mixers, Filtration system, Tank-farms and safety system, Utility equipments, etc.

Ensuring implementation of CAPA, de-bottlenecking in process, spares indigenization, engineering solutions, in place of admin. Control. Conducting Root Cause analysis and FMEAs to identify mitigation/corrective actions.

HT and LT System – DG’s, Transformers, stabilizers, breakers, switchgears, panels, Distribution Panels, cabling, switchgears, Equipments, fire detection, CCTV, Access controls, etc.

Managing all site activities, performed site inspection and quality control; implementing value engineering during various stages of projects thereby achieving cost & time benefits

Cost reduction Initiatives related to Power and Fuel consumption reduction, Process improvements, optimization of Equipments operations, etc.

Statutory compliance and Laisoning with Govt. Authorities, Vendor Management and Procurement, Finalizing Equipment/ Instruments specifications and ordering.

Budget preparation for spares/ repairs and consumables, maintaining critical spares availability, ways to reduce cost of carrying Inventory of Engineering stores.

Phthalic Anhydride Plant :

Plant Reliability: Preventive Maintenance, Modifications for process improvements in Oxidation and Vacuum Distillation section, Safety interlocks and Alarms, Projects execution, Process equipment’s, Stores and spares Management, Revenue/capital Budget.

Erection & commissioning and up-gradation of Invensys (Foxboro) DCS system.

Planning and execution of shutdown jobs during catalyst replacement.

Liaison, Manpower Management, Vendor development, Purchase & Negotiations.

Process systems: ISO (9000, 14000, OHSAS), Implementation of TPM methodologies, etc

Liaison works: Ensure to comply with various statutory/regulatory requirements viz.: IBR, Weights & Measures (Meteorological deptt), Electrical inspectorate, etc.

Also handled HR and Admin for 2 years, FG and by products dispatch including sales Maleic acid

Highlights:

Asset Care strategy : Monitored preventive/periodic maintenance appropriately scheduled and provided emergency troubleshooting & maintenance support availability. Factory Automation and installation/commissioning of Equipments.

New Technologies : Introducing and Adaptation of new technology – Robotics operation in Pick and place and palletizing, Auto storage and retrieval in warehouse, Packing machine Automation, IOT applications for cost reduction initiatives, Installation of PV Solar panels- capacity : 754 KW and integrating with EMI software for power monitoring

Projects : Planning and execution of various Capex Projects related to new products, Infra related to safety, Health and environment and respective compliances. Total 14 Projects completed in last 3 years with the total investment of 5 crores

Cost Reduction : Improved plant profitability and monitored performance of the plant functions including process engineering & low cost automation initiatives. Realized savings of Rs 60 lacs on SPC (specific power consumption) and Rs 20 Lacs on SFC (specific Fuel consumption) reduction in the last 3 years. Imported spares indigenization, Engineering stores inventory reduction from Rs 12 Cr to 10.50 Cr in the last 3 years.

Previous Experience

Jun’98 to Feb’08 with M/s Huber Chemicals (US Multinational), Gujarat

Joined as Instrumentation Professional and grown to Manager-Maintenance

Highlights:

Worked as a Six Sigma coordinator for two years; Identifying, Driving and execution of various Six Sigma projects in the plant for various chronic issues for process improvements, cost Reduction, waste Reduction, etc. Realized the savings of 1.2 Cr from 12 projects completed successfully in 2 years

Plant Expansion and Plant Automation through PLC system for Batch process control

Successfully improved equipment reliability and increased productivity

Developed improvement plan for equipment having more downtime; reduced downtime

Implemented GMP in maintenance of various equipment's/systems to support plant hygiene and 5S

Annual budget for spares/repairs & maintenance; Tracking budgeted figures and initiated cost reduction measures.

Tracking various utility consumption data reports of electricity, Raw & DM water, NG, Steam and various others

Dec’96 to Jun’98 with M/s Lupin Laboratories Ltd., Gujarat as Senior Officer-Instrumentation

Jun’95 to Nov’96 with M/s Heubach Chemicals Pvt. Ltd., Gujarat as Officer-Instrumentation

May’93 to Jun’95 with M/s Century Textiles, Gujarat as Assistant Engineer

Education

Post graduate Diploma in Operations Management from IGNOU, Vadodara, Gujarat in 1996

Bachelors in Electronics & Communication in 1992

Trainings Attended

PLC-5 series 'Programming & Troubleshooting' from Allen Bradley, New Delhi

Invensys DCS system (1300 I/O’s and 115 closed loops)

ABB DCS system (11000 I/O’s and 1200 closed loops) with RI/O panels in a domain network

Lead Auditor's Training on ISO-9000:2000 from M/s SGS (Baroda). Internal Auditor for Integrated Management system

Coordinator for Safety Management System, Behaviors based safety

Manufacturing Excellence : Six Sigma Green Belt Training for waste reduction and process improvements

Manufacturing Excellence : TRACC

Personal Details

Date of Birth: 24th January 1971

Language Known: English, Hindi, Gujarati

Address: Flat-D4, Asian paints colony, Ankleshwar-393002, Bharuch, Gujarat

Result orientated professional with expertise in managing entire Plant Operations, targeting assignment with an Organisation of repute

Location Preference: Gujrat

Motivator

Collaborator

Planner

Change Agent

M/s Uflex Ltd

M/s Asian Paints

M/s Huber Chemicals (US Multinational),

M/s Lupin Laboratories Ltd.,

Laboratories Ltd.,

M/s Heubach Chemicals (German MNC)

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