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Manager Plant

Bangalore, Karnataka, India
December 17, 2019

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Mohan Raghu Shetty

A: Nelamangala, Bangalore – 562123, India

C: +91-903*******

E: /

HEAD (Manufacturing & Operations)

Snapshot: Strategic Techno- Commercial executive, offering nearly 26 years’ of track record in Project Management (Construction/Site/Process/Maintenance),Operational Management Process/Quality/Technical/Commercial/ Administration), corporate management, maintenance and new business development in diverse roles across the organizational hierarchy. Exploring challenging senior managerial assignments with a professionally managed organization

Leadership Strengths & Highlights

Plant Operations: Skilled in enhancing productivity & profitability within the manufacturing process by optimizing resource utilization and implementing industry best practice/process improvement initiatives

Health & Safety Compliance: Well versed in ensuring compliance to quality parameters (incoming material quality, in- process quality and outgoing quality) and implementing various quality control methodologies

Process Improvement: Evaluate existing processes and procedures for redundancy and design new processes to match market dynamics. Analyze critical customer issues for identifying trends and implement effective mitigation plans for minimizing business impact

Managerial Acumen: Proven skills in managing teams to work in sync with the company set parameters & motivating them for achieving business and individual goals; Identifying specific talents and aspirations of employees and facilitating skill enhancement sessions enabling career growth for employees within the organization

Notable Career Accomplishments

Successfully worked on Challenging PROJECTS in Induction Furnaces,AOD converter of 08 / 12 ton capacity for Viraj Group (Indigenous), then IRS System of 20/30 ton capacity for Viraj Group, Supplied By PRAXAIR INC-USA (First in India), FES System For AOD (Modified).

Functioned as Consulting / Project coordinator between ET India and other prestigious clients such as Mid India Engineering Ltd. (Ruchi Group) for the Plant Layout up to commissioning, Global High-tech, Newtech, Gujarat NRE Coke and Neelakant Steels for finalizing layout.

Acknowledged for project implementation of Steel Melting shop (IF 20 ton x 2, 6 / 11 caster (CIL)) for Electrotherm India (Steel Division) at Kutch, E & C of First Indigenous Test Plant of 'Contifur (300TPD) and Blobulator'. E & C of DC / LRF of 11 tons for OSIL and 25 tons for ET and Banyan and Berry, DRI Plant (Rotary kiln 100 TPD x 2) worth INR 30 Crore for Haryana Steel & Power.

Implemented SMS (first 25 ton Induction Furnace by Electrotherm in South India) and CCM (Con cast India) division at Kunigal Karnataka for VIJAYAA STEELS LIMITED, Bangalore within the scheduled period of 14 months.

Headed 3 Iron ore Beneficiation projects worth 450 Cr in year 2011-13 at BARBIL,Orissa for 3 mining operation of KJSA,INDRANI PATNAIK and KMC, with 450+ staff including 15 subcontractors through THRIVENI EARTH MOVERS Limited


Diploma in Mechanical Engineering, Karnataka Technical Education Board (KTEB), Karnataka (1991)

Personal Details

Date of Birth : 15 June 1970

Languages Known : English, Hindi and Kannada

Nationality : Indian

Passport Details : Z2269042 valid till 2022

LANGAUGE KNOWN : English Hindi Kannada Tulu

~ References Available Upon Request ~

Professional Experience


General Manager (Operations)

Managed operational (Projects/Technical/Commercial) of the Sponge Iron plant/Melting plant client basis 25T * 2 / 6*11 Caster with 30TPH Rolling mill of making TMT Bars backward integrated by, Mining iron ore (CSW 100 TPH), & Proposed Integrated Steel projects .

Heading the team for Modification on Technology & Process optimization of first sponge iron plant in global by using 40-45% Ferrous Magnetite ore with 100% Indonesian coal for produce/ convert into long steel product through leased Steel melting/Rolling mill as promoting the base product of sponge iron/Reduction iron in Indonesian/Bangladesh market

Expansion projects on iron ore processing at Mining unit by proposed for Fabrication, erection, commissioning & of mineral processing plant of 100 TPH Crushing/Screening/Washing plant.

Business expansion in develop domestic market for sponge iron as the first plant of Indonesia, with the product of both Sponge iron lumps/fines /briquettes in Indonesia, First shipment of export order to Bangladesh executed

Engineering development and inclusion of 1000TPD aggregate plant with existing 1000x2 TPD aggregate units at sulevasi

CONSULTANT (operational Excellence)

STPL (STEEL Melting- MS) Mar 2016 -Nov 2017

Viraj Profiles limited (Steel Melting - SS) Dec 2017 –Aug 2018

Responsibilities: CONSULTING SERVICES (except factory occupation)

Function as Technical Lead for operational excellence including implementation of Integrated technical,5S concept, TPM,4M process in optimize productivity for their steel melting shops,casting unit and Hot rolling mill divisions ( INGOTS/BILLETS) in MS & SS

Render technical consultancy to the group to enhance turnover of INR 50 Crores to expand into INR 100 Crores by 2018 by expanding downstream export and import operation/system integration of raw material with self- sourcing and forward integration by adding manufacturing facility at Silvassa for an Indian owned MNC based at UAE.

Assessed & presented various status reports for the senior management & other stakeholders to enable effective decision making on Develop the Import material quality by upgrading MH System (import Machinery).

Due Diligence assignment with VIRAJ Group for their Maintenance/Process Management System Integration in up gradation of TPM and HRS (Human resource study) for their two RMHS/STEEL Mill producing 1200 MTPD of SS Billets

ERM Group 2013 –2016

Group General Manager – Operation Job Responsibilities:

Managed operations of SPONGE IRON - (2 x100 TPD Running, 4x100 TPD proposed), Project implementation of 0.1 MTPA Integrated steel plant (Melting/Casting/Rolling) for a mining giant from Karnataka with business interest in STEEL, Mining, Power, mineral processing and diversifying activity in value related as the profit center.

Involved in proposing future projects of iron ore crushing, screening, beneficiation and palletisation plant (0.6 x 2 Module) of three mining operations based on business & operational requirements.

Led two steel projects, Future Value added Government Supported Projects - Solid waste / Waste water treatment, Aggregates (2000 TPD/0.6 MTPA)

Conducted due diligence of 2 Integrated steel plant, 4 Mini steel plants, a foundry unit and 3 aggregate projects based on proposal for future acquisition and expansion.

Led profit center as social friendly environment for a continuous two year by the government authority (DOIC, KSPCB).

Thriveni Earth Movers 2011 –2013

General Manager – Projects Job Responsibilities:

Involved in end to end management of 2 Iron ore Crushing / Screening plants (1.2 -6.0 MTPA) and 3 iron ore beneficiation plants (0.8 - 1.8 MTPA) in Orissa.

Implemented prestigious projects with expertise in multidimensional execution for multiple mining clients in compliance to various contractual parameters.

Managed mineral processing equipment (Scrubbing, JIG, Thickener and Filter press units) for Beneficiation of Iron ore and processing of tailing constituents.

Focused on translating / realizing blueprints from location site to commissioning of Mineral Processing producing

O.3 MTPA to 0.6 MTPA Iron ore Crushing, Screening, Beneficiation facility, running maintenance and engineering developments.

Coordinated activities related to fabrication, erection, commissioning & trail operations of mineral processing plant having Iron ore Beneficiation plant (Scrubbing, JIG, Thickener and Filter press units) of 0.8 to 1.8 MTPA (3 facilities) for all minerals (Germany) and related utility and off sites and expansion projects.

Vijayaa Steels Limited 2005 – 2011

General Manager – Operations 2008 – 2011

Works Manager 2005 –2008

Job Responsibilities:

As General Manager – Operations ( RK 100*1, IF 12*2,15TPH HRM) –Projects ( IF 25*2,CCM 6*11)

Managed operational (Projects/Technical/Commercial) of the Sponge Iron plant, Steel melting shop & Proposed Integrated Steel projects of VSL.

Maintained updated knowledge of equipment from raw material handling to steel making (mild, stainless and alloys). Translated / realized blueprints from location site to commissioning of Integrated Steel plants producing 200, 000 TPA, running maintenance and engineering developments.

Coordinated activities related to fabrication, erection, commissioning & operations of Sponge Iron, Steel Melting Shop, mineral processing plant having Rotary Kiln with MH System, Induction Furnace, CCM and Hot Rolling mill, and related utility and off sites and expansion projects.

As Works Manager – Operations ( RK 100*1, IF 12*2)

Managed operations of steel melting shop & proposed Integrated Steel projects of VSL as member of team with expertise in multidimensional execution for Group Projects.

Coordinated translating / realizing blueprints from location site to commissioning of Integrated Steel plants producing 200, 000 TPA, running maintenance and engineering developments.

Worked on fabrication, erection, commissioning & operations of Steel Melting Shop, Induction Furnace, CCP, Hot Rolling mill, related utility and off sites and expansion projects.

Electrotherm India 2003 – 2005

Project Manager

Head of projects – 8 sites -Turnkey / plant layout, Equipment supply, E & C (Captive/Clients) and hand over Consists of Steel melting shop, Continuous costing plant, Rolling Mill, Sponge iron and pilot plants

Job responsibilities:

●Engineering co-ordination with HO /Client/supplier related to plant layout, feasibility, laisoning,

●Client/contract/supplier management in implementation of said assignment

●On site modification as per technical requirement as per process and location.

●Fabrication/Erection/Inspection/Commissioning of all plant and equipment.

●Conducting review meetings on target schedule, plan and assign work.

●Professional documentation/ facility management

●Up gradation of all system on made on drawings

●Handover of projects with review on performance

Viraj Alloys Limited 1994 – 2003

AE / SE / Assistant Manager

MAINTENANCE AND PROJECT MANAGEMENT – Team Member of Mechanical handled on process maintenance with expansion projects with the in plant developed crew for Steel melting shop, Continuous costing plant, Rolling Mill, Wire drawing units and forge shop

Job responsibilities:

●Preventive, Breakdown & Shutdown Maintenance of

1.Induction furnace having capacity 3/7/12/20 Tons of Electrotherm make

2.Argon Oxygen Decorbouriser (indigenious/IRS Praxair) 7/12/20 Tons – ET/MODIFIED

3.CCM – 4/7, TC Modified 6/11 Concast India

4.E.O.T. cranes having capacity 10/25/40/85 tons by FEDERAL ENGINEERS

5.Hot Rolling Mill – 14” modified to 18” next 24” (By PP)

6.Wire Drawing Plant by AMCO – Ghaziabad

●On site modification as per technical requirement as per process and location.

●Modified Fabrication/Erection/Inspection/Commissioning of all the plant and equipment.

●Involving in review meetings on target schedule, plan and assign work .

●All internal documentation according to QMS

●Up gradation of all equipment and system drawings (AS MADEON)

●Handover of projects with review on performance

Hofincons (Howard Finley) 1991 – 1994

Trainee Engineer / Junior Engineer


1.Site – ESSAR STEEL - HBI PROCESSING facility like


2.Site – ONGC (CPF Gandhar) – CSU, GCU, CFU, WWTP, OPU, Utility and Offsites

3.Site – VIL – Briquetting system

Job responsibilities:

Training on best engineering Work / Practices like

1.Handling of work i.e Shop floor /Workshop (fitting/carpentry/fabrication/sheet metal)

2.Handling of Tools (hand& Measure)

3.Handling of crew (Schedule /plan /review/target)

4.Study, evaluate,record, document the machine, equipment and work data

5.Training on Health, safety, fire, and first aid

6.System on work,safe wear/safe safety procedure/safe and right tool handling

History of Excellence in…

Plant Operations ~ Installation & Commissioning ~ Infrastructure Development ~ Quality Compliance ~ Health & Safety Compliance ~ Operations & Maintenance ~ Vendor & Stakeholder Management ~ Change

/ Risk Management ~ Industry Best Practices ~ Internal & External Audits ~ Resource Optimization ~ Cross Functional Team Coordination

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