VIJAY VILAS KANE

Contact: ***-957-***-****

E-Mail: addwhy@r.postjobfree.com

Dear Sir,

Please find attached my Resume for the position of “Unit Head-Intergraded Cement Plant. I'm particularly interested in this position, which relates strongly to my over 23 years of experience in Operations, Projects, Manufacturing Equipment Maintenance, Budgeting & Cost Control, Process / Product Enhancements, Techno Commercial Operations, Modification & Up-gradations Projects, Quality Assurance, Manufacturing Excellence and Knowledge Management.

As Business Head Engineering – Arvind Limited - Denim Business at Ahmedabad (Gujarat State),I believe I meet all the essential criteria of the position. Highlights of experience and demonstrated talent I would bring to your organization include:

Projects incubation to commissioning with 1st time correct with perfect timelines.

Efficient in ensuring stand-by equipment availability.

Entire experience in continuous process plants.

Successful in working in line with the concept & requirement of zero breakdowns, considering operational requirements.

Possess good communication, relationship management, team building and analytical skills. Handling Production as & when required from Top Management.

I am now looking for an opportunity to learn & faster growth.

I am attracted to this role on account considering mainly Projects - Maintenance exposure of 10 years in integrated Cement Plants (Larsen & Toubro Ltd.), 5 years in Ceramic Tiles Manu. H & R Johnson (I) then subsequent 4 years of exposure in Managerial skills at Top Management level as HOD at Substation Ceramic Insulators Manufacturing & 4 years now at Arvind Limited in Denim that it offers.

I appreciate your taking the time to review my credentials and experience. Looking forward to a positive response.

Thanking you.

Sincerely,

VIJAY VILAS KANE INDIA.

Enclosure: Resume

VIJAY VILAS KANE.

A/304, Fortune 361, Next to Vidyani School, Sama, Vadodara. (G.S)380009

• +91-957******* / 704-***-****• addwhy@r.postjobfree.com

linkedin.com/in/vijay-kane-0589582a

BUSINESS UNIT HEAD I HEAD ENGINEERING & SUSTAINABILITY

STRATEGY PLANNING OPERATIONS MANAGEMENT MAINTENANCE ACTIVITIES MANU EXCELLENCE I SUSTAINABILITY

Mechanical Engineer with MBA in Operations – Experienced Plant Engineering Manager leading high performing teams, driving innovation & maintaining Production assets by Preventive and Predictive maintenance. A savvy and passionate leader who leverages &to drive organizational results. Extensive experience in Mechanical-Electrical-Instrumentation-Civil Engineering, Supervision and Project Management. Record of improving profitability through cost reductions and increased efficiencies. Best-Pricing negotiations and innovative automation, long terms visionary with an eye on short term results.

CORE SKILLS

Strategic Planning

Productivity Improvement

Business Excellence & Transformation

Quality Assurance

Resource Optimization

Budget Management

Corrective, Preventive & Predictive Maintenance

Multi-Cultural Team Management

Green field Project Management

Leadership & Communication

Continual Improvement

Data Modelling, 4.0 Industry

TPM, 6 Sigma practises

Self Starter, Work under pressure

Problem solving & Critical Thinker

EXECUTIVE SUMMARY

Efficient Team Leader and Player, combining communication, interpersonal and problem-solving skills with analytical, decision making and leadership capabilities to enhance organizational objectives.

Proven problem-solving skills with the ability to anticipate roadblocks, diagnose problems and generate effective solutions.

Support towards new technology & product development.

Projects Management: New Technology adaption, Planning, Sequencing, execution which includes cost control, developing schedules, Liaoning with clients, resource management, risk Analysis and mitigation.

Industry expert having keen understanding of Project / Client Requirements coupled with hands-on exposure in handling all phases of Project.

Well versed in rendering consultancy to resolution of project related issues encompassing budget, completion date and resource allocation based on project contractual parameters.

Highly experienced in Spray Dyers, Piston pumps, Rotary Kilns, Shuttle Kilns, Preheaters, Hot generators, Filter presses, Rotary valves, Pug Mills.

Skilled in managing operational aspects of Utilities like Power distribution, EOT Cranes, Hoists, Lifts, Vacuum pumps, Air casters, Nitrogen Generator, DG’s, Caustic Recovery plant, NG distribution, Humidification plants, Boilers, Compressors, Water processing & management (ETP,STP,RO-DM).

Preparation of predictive and planned preventive maintenance programmes to maintain and enhance engineering systems availability and minimise risks.

Proven expertise in collating and evaluating data (Condition Monitoring (Vibration & Thermography), technicalities of Bearings, Lubricants & Gear boxes overhauling.

Training teams on 5S, TPM, Poka Yoke, JIT, PDCA, Kaizen & small improvement projects under 6Sigma umbrella towards continual improvement program.

Understanding & working with MIS and CEO for business EBITDA, P&L preparation.

HR - Staff recruitment, development – Technical Trainings, Succession Pipeline building, Performance Review, exit interviews, etc.

CAREER CONTOUR

ARVIND LIMITED, DENIM FABRIC & GARMENTING, AHMEDABAD, GUJARAT

Group Head Plant Engineering : Oct 2016 – May 2020

Responsibilities:

Plant Utility & Process Operation for achieving targeted production. Automated dosing of dyes & Chemicals (Green Acid, Sulphuric Acid, Caustic, etc). Production planning support & related execution.

Technical Support towards new innovate products development specifically – Knitted garments, Seamless garments, Laser products, Sustainable dyeing products, etc.

Green & Brown field Projects management for business. Capital Investment – Complete working with proposal including ROI, Approval, execution, On execution quarterly follow-up returns.

Lead, motivate and develop sustaining engineering team (Mechanical/Elect/Instrumentation/Civil/Projects/Utility) having size of +400.

Business Risk assessment and plan for Asset Maintenance (Fabric - Spinning, Dyeing, Weaving & Processing for 9 million meters fabric/month.&4 units of Garmenting facility including cutting, Sewing, laser, Washing & Drying including related Utilities operation)- Anticipate Business risk and Establish and ensure implementation of predictive and preventive maintenance (Mechanical, Electrical. Instrumentation & Civil) systems and control for maximum availability of plant and equipment within maintenance budget to meet production requirement. Usage of CAPA, SOP’s, JSA, HIRA towards it.

Efficient use of Fixed and Capital Cost - Repair & Maintenance and Project cost - To ensure maintenance of equipment and continuously bring down R&M cost to bring down fixed cost Anticipate and plan for budget in consultation with respective department and obtain approval Periodical review of cost and consumption to reduce maintenance cost and control the same by taking timely corrective action Monitoring and control of deployment of all types of labor forces to ensure all activities within budgeted norms.

Design new equipment’s, processes, procedures & systems. Purchasing & installation of equipment’s.

Fixed and Variable cost reduction - Formulate and implement cost reduction strategies in plant maintenance and energy consumption - To develop strategies for cost reduction for Plant maintenance and energy cost reduction

Conducting in - house / outside party energy audit to identify potential area. Prepare and implement return based schemes for their implementation

Coordinate with heads of production and process control for implementation of cost reduction plans Monitor all cost reduction plans and highlight slippages to user Department and Unit Head Identify areas to improve maintenance quality and reduce costs, and ensure implementation of these plans.

Inventory Management - Develop system for inventory control to ensure adequate inventory of spares Monitor indent raising to allow only required and to be immediately consumed items on receipt.

Systems Management - Guide and provide resources for effective implementation of Business Excellence and all relevant Integrated Management Systems like ISO - 9001, ISO 14001, ISO-18001, ISO-50001 review and monitor progress Ensure the team gets exposure to new developments in systems

Ensuring Utilities availability/Operation for - 8MLD STP, 10MLD ETP, 500 KLD ZLD, 60T steam generation, 20000CFM compressors, NG gas distribution, 250m3/hr Nitrogen generation, Chillers, 250kWP Solar power & 2.8mW Wind Power generators, DG’s, Power distribution for entire 7 campuses.

Accomplishments:

New end to end Green field Knits & Denim garmenting facility developed (990 sewing machines) in 316 days against scheduled 355days worth 120 Cr at Bavla.

Accomplished 1st time accuracy with scheduled timeline for 36 Rope dyeing-Foam dyeing-Stentor & Knits set-up installation which includes machine requirement finalization, Procurement, Inspection, installation, erection, commissioning - 78 Crs.

Minimized power consumption reduction by 15% in 3years duration. Enhanced boiler efficiency improvement from 86% to 91% by Nozzle modification & SCADA with VFD and utilizing alternate fuel (DOC) for Boilers.

Optimized maintenance cost from 13Cr to 8Cr by close tracking, alternate sources development, optimization of equipment, modification of repeated failing components.

Successfully set up solar power for 990 Kw. Bagged SEEMs Platinum awards for continuously for 2 years and got short listed for the BEE award.

ADITYA BIRLA INSULATORS, HALOL, GUJARAT

Head Engineering – General Manager Jun 2012 – Sep 2016

Responsibilities:

Led Engineering team having 4 section heads & 112 (27+84+1) workman including technicians.

Foster and created a highly collaborative culture within team using best practices & delivery excellence.

Attending & completing the breakdowns of machines, utilities & Material Handling equipment within the least possible time. Implementation of systematic approach for repetitive nature of works. Analyzing and implementing counter actions / fool proofing for repetitive break downs. Establishing & Implementing Preventive Maintenance schedules.

Cost control by proper planning of spares. Obtaining the expenditure every month, monitor the same and take appropriate actions in the areas of method, material and training of operators

Responsible for planning & estimation of budget for the capex. Co-ordinate with all section heads to prepare capex requirement & improvement plans in terms of quality, yield, productivity, reduction of cost. Ensure preparation of Cost estimation & calculation of ROI. Ensures preparation of schedules in consultation with Purchase deptt. Preparation of design & specifications. To plan, execute & monitor erection & commissioning activities in adherence to planned schedules.

To co ordinate with commercial deptt for procurement within scheduled time & budgeted cost.

To ensure continuous improvement in the plant operations & technological up gradation. To monitor for compliance of all statutory & legal requirements, safety procedures.

Critical machine i.e Pug Mills & CNC machines-100% PM schedule adhered for ensuring reliability of processed product.

Establishing key performance indicators to consistently measure and track Sustained Engineering team performance

Ensure the team's availability when critical situations arise, deploy resources to help resolve customer reported technical issues and ensure customer satisfaction before closing the escalation.

MTBF & MTTR monitoring on daily basis with target to achieve planned production.

Accomplishments:

Initiated ROI based Brownfield projects including debottlenecking (Slip house slurry preparation, mixing & homogenization ) CAPEX of INR 22.78 Cr and resolved various GPCB, MGVCL legal issues.

Optimized annual maintenance costs by INR 42 Lakhs by implementing various projects.

Eliminated Pug mills stoppages due to low vacuum/fluctuation by replacing Bosch vane vacuum pumps & chillers for barrel cooling. Improvement in dispatch-able by 2.8%

Worked as 6 Sigma Champion for Pug mill extrusion speed variation reduction leading to 0.8Cr/annum saving on successful implementation.

World class manufacturing – Excellence based model - Implemented related processes & methods for Engineering function.

H & R JOHNSON (INDIA), RAIGAD, INDIA Oct 2007 – Jun 2012

Responsibilities:

As Mech. Maintenance HOD – Deputy General Manager, Sept 2009 – Jun 2012

As Senior Manager, Oct 2007 – Sept 2009

Managed major maintenance of main support/eccentric housing for SACMI, Italy make MTD-340 supplied 16 ball mills (20T capacity).

Ensured 100% compliance to PM of all tunnel Kilns as per schedule, rolled out 100% Vibration monitoring and expedited action for achieving zero breakdown of Kilns.

Rolled out projects related to optimization of energy consumption by 2% every year. Followed up with concerned stakeholders in maintaining mechanical and electrical expenses within budget.

Replaced with low speed fans reduction of wear rate of impeller and power consumption. (1,10,000 m3/hr capacity). Rolled out systematic method of maintenance activities throughout the plant in-line with TPM guidelines.

Worked on erection and commissioning of 8 Nos. HOPE flat print machines, double disc booths, tile loading / unloading B&T machine, material handling flat belt conveyors, SACMI-Italy high pressure piston pumps PPB313, wax applicator, ball mills, etc.

Conducted technical trainings on AODD pumps, MTD340 ball mills, Screw Compressors, B&T tiles loading / unloading machines, Vibro-sieves, Bearings, lubricants, vibration monitoring & static – dynamic balancing etc.

Guided the maintenance team of 2 Dy. Managers, 16 Engineers, 12 Team Members and 76 associates pertaining to day to day operations. Rolled out TPM across the manufacturing facility.

Accomplishments:

Played a key role in improving upon the equipment health & availability leading to reduction of process losses and subsequent improvement in product quality level from 65% to 90% with 99.5% up time.

Successfully commissioned 2 Nos. Digital Creta, Spain Printing machine project (3.5 Cr each) for the first time in India in May 2011.

Enhanced service level and quality from 65% to 90% in 2 years duration as well as improved bottleneck equipment (Kiln) availability to 99.5%. Initiated TPM for entire plant and conducted awareness sessions for Staff & Team members.

Rolled out Predictive Maintenance i.e. Vibration monitoring & actionable resulted into plant critical equipment’s availability/reliability to 100% level specifically for Slip House & Kiln fans.

Reduced breakdown by 70% for MTD-340 SACMI, Italy make ball mills major bearing by implementing drive shaft failures analysis-action plan for rectification, design reworking, new grade modified shaft development with specific tolerances.

Generated savings of 40% heat energy at Slip House by setting up waste heat recovery unit (Turbomach-5mW gas turbine Operation & maintenance).

Saint Gobain Glass India Ltd., Chennai Team Member – Technical Services (Mech.- Batching & Furnace), Nov 2005 – Sep 2007

Responsible for Mechanical Maintenance of Batch House & Furnace equipment availability which includes PM & Predictive maintenance.

Larsen & Toubro Ltd – (UltraTech Cement Ltd.),Awarpur Cement Works, Awarpur. (Maharashtra State)

Sept 1996 – Nov 2005

As Assistant Manager (Mechanical Maintenance)

Highlights

Handled FLS, Denmark supplied Line-1 & 2 complete Preheater, Kiln, Cooler, Deep Bucket Conveyors, Coal Mills (Atox, Tirax) and Coal handling plant.

As Sr. Engineer

Highlights

Kiln-II middle tyre with shell replaced as earlier tyre was having repaired for cracks. (4.55*68mtr long – 3.8 rpm) 42T Live ring, 4T chair pad, Kiln shell -21T. Complete job (78tons) was executed with mentioned steps in a period of 17 days.

Performed 5 Why Analysis & FMEA for reducing component failures / increasing life of components through 6-Sigma.

Induced eye opening changes at Site Stores by housekeeping with 5-s implementation for it’s sustainability.

PH-I cooler & coal mill fans dampers removal i.e. W1K12, W1K13, W1K14, W1K15 & K1P56 – 10.4KWH/day saving.

Achieved extension of Calciner–I Vessel by 1560mm, successful in improving burning efficiency as well as reducing the difference between material and gas temperature from 40 degC to 25 degC.

Kiln & Calciner Down-Comer Duct (70 Ton) dia. Enlargement from 600mm to 800mm for reducing power consumption by 20 Kw & reduction in coating formation.

For clinker cooling Swing cooler arrangement provided which was controlled clinker temp to far extend. Pneumatically operated auto sampler installed for collection of clinker sample at hammer mill discharge for collection of average hourly clinker sample.

Kiln HRCS Gr9 tongue plates & outlet sectors life enhancement by modifying provision for holding castable.

This increased life from 1 year to 3 years without wear/damaging HRCS sectors.

Reduced fugitive dust emission levels from 1500NMg to 870 Nmg by deducting unit suction points modification.

Inspected Kiln Ist&IInd Pier Support Roller Bearings Liners, scrapping and replacement for all 24 bearings of 340 & 400mm size.

Successful in increasing life for Cooler First Grate Plates Tero-Coating (XHD2222 & 9120 eutectic products) & Retention Box from 7 months to 12 months.

Replaced Clinker hammer mill hammers with high chrome hammers which has improved life to 12 months duration including reversal.

Maintenance of Raw Mills, Cement Mills, Separators, Stackers, Reclaimers, GCT, ESP’s done. Handled Mechanical W/shop all activities independently as Section Head.

Complete Course attended on TPM & 6 Sigma by M/s. Eicher Consultancy Services provided in the organization. Implemented as per guide lines step by step at all level. Green belt cleared in 2003.

As Engineer

Highlights

Kiln Drive Girth Gear Reversal & replacement done for K1 & K2. (K1 - 7108mm PCD, 280 Teeths, 25.4 Module, Face width 500mm, Straight Spur, wt-12.5t).

Kiln Pad Plate & shimming jobs done time to time during major shutdowns for kiln migration purpose.

Provided support during Kiln Support Roller &Tyre Grinding by Phillips Services.

Converted Tirax Coal Mill into Boltless Liner Mill.

Predictive Maintenance done i.e. Vibration monitoring by IRD Mechanalysis for all Kiln Eqpts. Good exposure in vibration analysis & balancing. Dynamic balancing done for 4 years duration.

Aligned:

Duo-Flex Coal Firing Burner.

Cooler Grate Driving Cross-Girders & Beams.

As Graduate Engineer Trainee

Highlights

Handled installation & maintenance of high efficiency &High Speed Smoke Gas Fans, Cement Mill-4 Combidan Diaphragm shifted for increasing operational efficiency & reducing special power consumption of the mill. (110 t/hr. To 130 t/hr.).

Shift maintenance of Raw Mills, Kilns & Cement Mills done. Along with this Preventive maintenance scheduling, predictive maintenance like vibration monitoring, WDA oil analysis, Thermography techniques learnt and adopted.

PROFESSIONAL DEVELOPMENT

Undergone 20 days Vocational Training done at NTPC, Kawas Gas Power Project, Surat. (G.S.), June 1996

Cleared 30 WPM Exam passed in B Grade and rendered excellent support in computer operation

Active participant in trainings like Managing the Managers – 05 days, Bulk material handling technologies – 03 days

Acquired expertise in Condition monitoring, Bearings, Gear boxes, lubricants, Bulk material handling, Managing Managers, etc

Certified Green Belt from Eicher consultancy.

LMI - Leadership Management International by Paul J. Meyer – 1year duration course -2016.

TOOLS & METHODOLOGIES

Possess knowledge in SAP – PM & MM modules for mechanical maintenance

Skilled in working on Windows, MS Office, AutoCAD R-13, Mini – Tab & Internet Applications

EDUCATIONAL QUALIFICATIONS / CERTIFICATIONS

Full time residential 3 Tier Senior Leadership Program as Alumni of Indian Institute of Management, Ahmedabad.

Certified WCM Accessor - Program conducted by M/s. Aditya Birla.

MBA – Operations Research, I.G.N.O.U., New Delhi, 2003

oSecured 4 points grade out of 5

BE (Mechanical Engineering), Amravati University, Amravati (M.S.), 1996

oDistinction grade 75% (Awarded as College batch topper for the year)

PERSONAL DETAILS

Date of Birth: 15 March 1975

Nationality: Indian

Passport No: J7912811 valid till: May 2021

Language Proficiency: English, Hindi, Gujarati and Marathi

Address: B-24, Sharanam-8, Next to Satyam Status Building, Jodhpur Gam, Satellite, Ahmedabad – 380015, Gujarat, India

Contact this candidate