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Plant Power

Location:
Secunderabad, Telangana, India
Posted:
September 25, 2019

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Resume:

Inderjeet B. Tech & MBA

Personal Summary:

A senior techno-commercial Cement professional consistently outperformed the industry in key metrics such as capacity utilization and consolidation of Realization & profit enhancement in Cement manufacturing business. Spearheading entire Cement Manufacturing, Implemented & commissioned Four brown field projects one each for Andhra Cement, UltraTech cement, Holcim – Lafarge & ETA Star International & accelerated Capacity from 1 MTPA to 2.5MTPA with Installation of Roller Press & Grinding station, three Green field projects of Integrated Cement Plant 1.5 MTPA FLS Plant, 1.5 MTPA Thyssen Plant & KHD plant 2.5 MTPA. Steering strategic business objectives with in-depth knowledge in Plant Operation & Maintenance management by implementing safe & Innovative techniques within time bound schedule, based upon the strong planning & execution acumen. Successfully accomplished the targets within stipulated budgets. Also carried out Cement Plant Modernization, Up-gradation & Process Optimization and set Benchmarks in improving efficiency and adapting usage of alternative fuels and raw materials to cut CO2 emission. & greenhouse effect. Awarded for Best practices like TPM and World class manufacturing techniques setting SOP in Safety, Quality, cost, productivity & logistics.

Began carrier with US$40 Billion Corporation, the Aditya Birla Group, UltraTech. Sharpened skills in Operational Management with Specialization in Risk management through e-MBA from ISMS Mumbai. Experienced in operating Cement Integrated Unit with KHD. FLS. Thyssen Krupp polysius, Peter Claudius as well Chinese technology Supplier like Sinoma and Citec.

Possess Capability of building target-oriented team by system integration & implementing management tools. Strong managerial background forged with senior level experience in Indian & International Market gained cross sector exposure. Good strategic appreciation and vision, able to build and implement sophisticated plans with a proven track record explicitly supporting business needs. Self-driven and self-reliant, sets aim and targets and leads by example, collaborative approach with good interpersonal skills to engage, motivate and encourage others through change. Presently looking to continue a career in senior management level with major objective of contribution to organization on long term & sustainable basis.

Profile:

A mechanical engineering professional having 27+ years solid experience in techno commercial aspects of Engineering, Project, Operation, Quality Assurance, Marketing, HSE aspects in the industry.

Employments include HOLCIM Ltd, ADITYA BIRLA GROUP AND GERMAN MNC

Expertise in:

Project related engineering, planning & controlling of plant & machinery (P&M).

Erection and commissioning of all kinds of Rotary equipments viz Kiln, Grate Cooler, Pre-heater, VRM, Ball Mills, Material handling equipments Pollution control equipments (ESP & baghouse), packing unit, structural, pipeline & fabrication works.

Planning & execution for Installation of Static Equipments like Boilers & pressure vessels as well maintenance of boiler component, including pressure parts,

Manpower planning and controlling.

Plant up-gradation and modification work

Plant Maintenance Scheduling by Com’s, Cempac (TCS) & SAP.

Condition monitoring of plant critical equipments (Fans, G.B. & Mills etc.), all types of kilns, mills, crushers (L&T, Hazemag etc) & auxiliary equipments with special skill in their erection, commissioning and operation and maintenance.

Experienced in implementation of:

ISO 9002, ISO 14001

TPM, Lean production, Six Sigma & WCM.

Demonstrated abilities to perform under pressure and deliver results amidst tight schedules, possess strong problem solving and analytical skills.

Adept at Pollution Control.

Innovative in applying energy conservation method used in the manufacturing process.

Professional Experience: 27 yrs 02 months

5.) National Cement Co ltd: Unit Head / Plant Head Nov 2016 till now

AFRICA

Reporting to MD and spearheading entire operations with Cement Manufacturing, Cement based products like fibre cement roofing sheets & precast manufacturing, RMC (Ready Mix concrete) units, Aggregate, building materials & allied products with Targeted maximum Capacity Utilization leading a team size of 1000 employees.

KRA:

Overall P&L of all Departments, Organization.

Align smooth efficient operation of Plant & accomplish targeted net profit margin.

Increase profitability (EBITDA) by enhancing productivity and efficiency.

Achieve agreed target against approved budget for Operations & Maintenance

Facilitate all engineering planning & environmental monitoring systems

Regulate material and sub-contractor management systems with SAP

Enabling disciplined Capex spending & timely completion of projects

Ensure procurement within stipulated budget & Inventory control.

Process & Technology up gradation to revitalize Productivity.

Maintaining safe, Hygienic and Pollution free Work environment.

Strengthening Cement Sustainability Initiatives / CSR & HR training.

Completion of statutory formalities in time & finalization of audit on time.

Identification and reporting risks and providing inputs on risk mitigation

Inspire Leadership Qualities, Mentoring and foster employees’ motivation

Accelerate Sales, Marketing & Branding of Cement & Allied product

Strategically Quality control to meet International standards & Customer Delight.

Achievements:

Increasing 30 % Production (7 m$ /Annum) by implementation of Focused plant improvements (Kaizen) & Technology upgrade projects in strict Timeline and allocated budget.

Saving of O & M cost by 20% (10m$/ Annum) improved margins significantly helped by improved efficiency and a much better fuel mix

Increase in sales Volume by 10% & hence revenue generation by 35% approx.

Saving of 2.5 m $ /Annum by utilizing idle assets and obsolete machinery.

Organization restructuring & Streamlining achieved 15% indirect cost reduction (1 m$/Annum) in operations.

15 % reduction in Inventory (1 m$ /Annum) by proper management of spares, tools and Planned Maintenance.

Eliminating Packaging losses which contributed saving in tune of 1.0 m $/year.

4.) ETA Star International LLC Dubai: Head Operations & Plant Head May 2013 to Nov 2016

Fostered Overall O&M, commissioning, plant start ups and stabilization of Integrated Plant on Turnkey basis on Behalf of ETA Flagship and handled plants at following three locations and handling 1000 employees including Expat and Locals.

# Fabrica de Cimento do Kwanza Sul (FCKS) 1.5MTPA / FLS / Angola, AFRICA #

# Alsalam Cement ACPC / Thyssen Krupp / 1.5 MTPA Sudan, AFRICA #

# SBRCCL – Binani 2 MTPA / 6500TPD China, ASIA #

KRA & Achievements:

O & M, plant commissioning in stipulated time and allocated Budget with Overall P& L.

To achieve the plant rated throughput from limestone to packing plant.

Quality of Clinker and cement as per International standards.

To adept for Maintenance practices and operational capabilities to Client.

Implement modification to remove bottlenecks of plant.

To design and implement Safety and in-house training programs for staff & workmen.

MIS and Logistics support for Sales and marketing of Cement in Angola.

3.) ANDHRA CEMENTS LTD: Senior D. General Manager – Tech Sept 2010 May 2013

2.5 MTPA Integrated Plant Guntur, Telangana, India

Reporting to the President (W) and leading a team of more than 1000 employees, which include managerial staff, Wage Board employees as well contract workers, permanent employees & lower Staff.

KRA:

Overall P&L and Complete Operational & Maintenance Management of Plant.

Annual Production Planning and Budgeting & ensuring Targets

Heading Task force Team for Process Controls (Heat Balance and False air reduction).

Implementing ERP like SAP Plant Maintenance & Production module.

Productivity improvements and cost reduction

Implementation Alternative fuels Systems from HFO to other solid fuels.

Implement Safety and in house training programs for staff & workmen.

Ensuring Quality of products as per International standards.

Organising for Daily, Monthly Meetings for Improvement & strengthening MIS to Apex Management.

Achievements: Timely Project accomplishment for Plant Capacity enhancement & Major Up gradation from 3000 TPD to 6000 TPD

2.) HOLCIM – LAFARGE -ACC LTD: Manager - Technical Jul 2007 to Sept 2010

5.5 MTPA Integrated Plant Wadi, Gulbarga, Karnataka, India

Reporting to the Unit Head and initiated Geocyle (AFR) & Co processing in wadi & Navigated team size of 300 employees. Laisoning with Govt agencies like CPCB & KSPCB & international agency SGS for establishing sustainability of Quality of Clinker with AFR techniques and captured carbon footprint firstly in India INR 2.5 Lacks.

KRA:

Completing operation & management of Pre & Post Clinkerisation (3 complete lines / 5 MTPA) & Power Plant (up to 200MW) as well captive power plant (25 MW) based upon Coal & Bio Fuel

Achieving annual production targets by means of operations of Crushing plant, Mills & Kiln, etc. with Grinding Media & Refractory Management.

Daily production Review, B/D analysis and action plans.

Plant budget, critical spares follow up with OEM & supplier.

Capex Jobs Block preparation, sanction and implementation.

Implementing SAP PM & PP module.

Implementing down the line Plant Safety Audit Reports.

Demonstrating the quality assurance procedures to customers on factory visits.

Ensuring that all targets are achieved within the limits of budgeted costs.

Formulating strategy for new product launching/Scheme in the Market.

Operating as a final recommendation authority to Unit Head for departmental candidates in respect of promotions, salary raise, probation extension or disciplinary action.

Keeping check on quality / promoting technical/ R&D activity for the entire plant.

Making constant effort to create break through improvements in products marketed.

Ensuring operational safety across the entire plant.

Assessing manpower requirements, interviewing and finalizing selection of Safety Officers and Safety Manager.

Liaised with govt authorities like civil defence, police and municipality, and also with clients for matters of safety and external administration.

Providing inputs for safety manual preparation & getting approval from appropriate authority.

Complying with environment regulations and implementing ISO 140000.

Ensuring:

Safety audits on regular intervals.

Good house keeping of factory for safety, neatness and quality.

Achievements:

INR1.5 Crores GAV achieved by using AFR.

Reduced down time of three kilns from 7 days to two days / month.

Installed Cooler ESP in place of old multi cyclone technology and thus limited to 50 from 200 ppm/ncum.

Received AFR Innovation award from Golden Peacock.

Selected as a leading member of team in getting QMS, EMS & OHSAS certification.

Leading member in manpower productivity enhancement.

Maintained zero accident rate in plant.

First cement plant rewarded with Pollution Control Award from Madhya Pradesh Pollution Control Board.

Sold 50 % scrap material in plant realizing INR 75 lacks

1c.) ADITYA BIRLA GROUP - RAJSHREE CEMENT: Deputy Manager (O&M) Sept 2005 –July 2007

5.5 MTPA Integrated Plant Gulbarga, Karnataka, India

Reported to the VP (Technical) and controlled 200 employees.

KRA:

Complete Erection, commissioning and there after O&M of Pre-clikerisation (3lines of Kiln, Coal Mill, and Raw Mill) & Raw material Transport.

Reviewing Daily production & Maintenance planning to maximise production.

Planning critical spares and follow up & Budgeting.

Carrying out improvement of jobs based upon why-why analysis of repeated breakdowns.

MIS Reports, correspondence and other follow up records with OEM & suppliers.

Modernisation of wagon tippler and side arm charger and zero spillage in coal transport and coal accountability.

Implementation of SAP & training to front line supervisors.

Liaising with govt. and local regulatory authorities.

MR for quality ISO 9001 and enforcement of quality systems.

Erection & maintenance of Crushing plant, Mills & optimizations

Allocation of duties and responsibilities of Train Operators for Mills /Kiln Operation.

Raw material Planning & Handling.

Energy Conservation.

Pollution control –Monitoring, maintenance & reporting.

Achievements:

Erection/commissioning of plant in scheduled time.

Optimized Mills production.

Third generation classifier installed in Coal Mill II & III and increased output by 5 & 8 Tons/ Hour respectively

Side arm Charger up-gradation and modification in–house Saving INR 350/- Lacks done in March 2007.

Major up-gradation in Coal transport system by extending longitudinal pile extension and extension of existing belt conveyors and providing huge covering Shed for e-grade coal for power plant hence recovered 2 Crores in pay back of two years.

Started in house repairing of Roll press rolls saving 25 lacks / yr / Roller press.

Implemented WCM and Autonomous maintenance practices saving manpower cost by 5%.

Zero accident in Plant.

1b.) ADITYA BIRLA GROUP - BIRLA PLUS CEMENT : Assistant Manager Dec 2000 – Sept 2005

2.5 MTPA Grinding Plant Bathinda, Punjab, India

Reported to the GM (Technical) and handled 150 employees.

KRA:

Project engineering.

Erection and commissioning of complete plant.

Planning of spares & budgeting.

Installing Roller Press to enhance production and reduce power.

Making correspondence and other follow-up records with OEM & suppliers.

Overseeing plant operation and maintenance, liaising for fly ash and land acquisition & power.

Holding training classes for fresh graduates.

Achievements:

Implemented the project within a record time of 11 months with nil accident report.

Full capacity of production 155 TPH achieved within three months after commissioning of the plant..

A major breakdown of main drive occurred (due to electric current leakage) which was rectified within three days working around the clock with in-house manpower in absence of M/s Flender's representative. This resulted in saving around INR 25 Lacks, which would have been otherwise incurred on account of possible loss of production, and repair charges to the company.

Installed Raw Material Handling System for fly ash i.e. Dense Phase System 80 TPH, Fly Ash conveying by 1 Kilometre Line supplied by Fuller India Ltd. That was done for the first time in India at that point of time.

Implemented Cempac (TCS) for maintenance system later upgraded by SAP.

Maintained zero accident rated in the Plant.

1a.) ADITYA BIRLA GROUP - VIKRAM CEMENT: Senior engineer/Engineer June 1992 – Dec 2000

4.5 MTPA Integrated Plant Khor, Neemuch, M.P, India

Reported to the DGM (Mechanical) and handled 100 employees

.

KRA:

Scheduling routine maintenance & execution.

Planning maintenance, execution & manpower allocation.

Planning stocking of spares.

Attending breakdowns, undertaking modernisation & up gradation jobs of Plant project work.

Preparing monthly performance reports of Kiln, Raw mill, Coal mill & maintaining records.

Monitoring condition of critical plant and machineries on daily basis and rest as per pre-drawn schedule.

Responsible for operation and maintenance of utilities.

Achievements:

Implemented TPM in plant and became first cement plant in India to receive TPM Award from JIPM Japan.

Implemented Quality Systems: ISO 9002, ISO 14001.

Carried out replacement of Kiln Shells (Burning Zone), Inlet Drum and Outlet Seals, Chair plate adjustment & replacement, Tongue plate fabrication & replacement, Brick retaining plate in house fabrication and fixing.

Repaired cement mill shell crack & VRM FMG make planetary Gearbox (42 MT) housing crack work.

Maintained a nil record of accident in plant

Trainings:

National Seminar on hazardous Materials Management ACHMM

Workshop & Training Course on Hazardous Materials Management

Symposium on " New trends and Challenges in SHE Management in Hazardous Industries" on occasion of Chemical Disaster Prevention day 2007

Teamwork and leadership management distinction

Fire, Safety & Environment

WCM Conference cum Workshop

Successful implementation of Bathinda project

Training of hydraulics & its application in cement Plant

Heavy fabrication in Turbine manufacturing and manufacturing of turbine blades & Rotor balancing in Vacuum Tunnel.

Education:

B. Tech. (Mechanical), H.B.T.I, Kanpur, 75%, 1992, Scholarship holder for all the four years.

MBA in Operational Management (‘A’ – Grade) with Specialization in Risk Management.

Computer Skill:

MS-Office, Windows, Cempac (TCS), AutoCAD, Infinitesimal (CAM), Primavera & SAP Modules.

Personal Details:

Date of Birth: 04-05-1969

MARRIED

Languages known

Speak Read Write

Inderjeet Singh Sidhu

Address: H. No 6-1-90/33, BapujiNagar, Musherabad, PadmaraoNagar Secunderabad, Hyderabad Telengana India ZIP: 500020

E –mail ID: adafwq@r.postjobfree.com

Cell1: +91-949*******

Cell 2: +91-630*******

English yes yes yes

Hindi yes yes yes

Punjabi yes yes No

Telugu yes No No



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