Plant Manager

CURRICULUM VITAE Page *

PADMA VIBHUSHAN SHUKLA

CEMENT OPERATIONS MANAGER

Doha-QATAR

Ph: +974********

I am well experienced Cement Operation professional of 29 years’ experience who worked in different positions with various Cement & Concrete Plants in Middle East and India. I use my skills and potential to lead & assist an organization team in achieving its goals with optimum growth. This objective would be supported by my qualification, in addition to my experience, my own interpersonal skills, motivation, leadership, public relation and multi-lingual command.

Presently working as Cement Operations Manager in Qatar. My top Priority to achieve & above of KPIs, Safety with Zero LTI, Quality, Environment & Customer satisfaction with maximum productivity. I lead entire Plants of all departments from Quarry to Cement Dispatch and motivates my team for smooth operation with maximum output & minimum break downs. Maintaining effective team spirit, good public & personal relation, Business development and cost-effective Ideas. Worked in several green field integrated Cement projects for Commissioning, Operation, Production, Process Optimization in India and abroad.

I worked successfully for documentation, implementation & certification of ISO, MIS & API standard in several Cement Plants.

Worked with world biggest Cement player like LAFARGE, HOLCIM, CEMEX, Ambuja & Aditya Birla Group.

E-MAILS:

************@*******.***; ************@*****.***

Web Site: https://www.linkedin.com/in/padma-vibhushan- shukla-7600b918/

Skype: pvshukla1

CURRICULUM VITAE

SUMMARY

• Name: PADMA VIBHUSHAN SHUKLA

• Profile: Male, Married

• Nationality: India

• Current Location: Doha-QATAR

• Current position: Operations Manager

• Company: SHIFT GROUP WLL, Doha, Qatar

• Reporting to: Group CEO.

• Professional Expertise: 29 Years of proficient experience in the field of managing KPIs, Safety, Operation, Planning, Execution in highly challenging environments of the Construction Industry

• Language: English, Hindi, Arabic

• Permanent Address: 502/503, Raunak Villa, Race Course, Indore-INDIA WORK EXPERIENCE

July 2019 till date AL SEHMIAH CEMENT, SHIFT GROUP WLL, Doha-QATAR Operations Manager

Responsibilities:

Working with Al Sehmiah Cement of 1.6 Million tons Cement Production, it is a subsidiary of SHIFT WLL Cement & Concrete in Doha, Qatar since July 2019.

Maintaining motivated cost-effective team with excellent leadership, making good personal & public relation for smooth plant operation & business development, continuous motivate the staff for Safety, excellent productivity, best quality, cost efficiency & energy saving. Responsible for KPIs, Safety, Operation, Production & Maintenance, Quality Control, Logistics, Procurement of Raw Material & Alternative Raw Material

& Fuel, Concrete & Finished Goods supply.

Closely monitoring & discussion with team for day to day Production, Quality Parameters, Process, Operations & Method for planned condition- based maintenance to reduce the break downs.

Daily, Monthly, and annual Production planning as per market demand of OPC, SRC & Oil Well Cement, Concrete mix, Concrete blocks & Paving stone with coordination of Sales team.

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Responsible to follow up for maintenance, break downs, Quality of Raw material & final products, and supply of finish goods with Packaging & dispatch team.

Monitoring Hourly, Daily, monthly & annual Production, Quality & stoppages reports, monthly & annual budget, break down analysis, RCA, Manpower managements, Sp. Power Consumption & cost reduction. Maintaining good relationship with Procurement team & Suppliers to negotiates best quality & price of Raw Material, fuel, spare & services. Documentation, maintaining & follow up of ISO certification Working with ERP system of Microsoft Dynamics 360

Planning with HR team for recruitment of staff and training for motivation

& Multi-skill development inhouse or external, Group discussion & Seminar for employees. One to one discussion & reachable for all employees for their grievances, maintaining best relationship with staff. Developing, Setting & tracking of the performance parameters & objectives for current & next level of employees and Bi yearly & annual appraisals of individual & departments.

Monitoring the Daily, Month & Annually Inventory Management & Stock count with Mines & Production team, Warehouse, Account team, Surveyor

& Auditors.

Inspection & monitoring of Staff accommodation, canteen & food supply. All technical HOD including Warehouse, Logistic & Procurement reporting to me.

My reporting to Group CEO.

May 2014 to July 2019 Al Khalij Cement, QATARI INVESTER GROUP, Doha-QATAR Production -Head of The Department

Responsibilities:

Headed the Operation & Maintenance of two FLS Plants of 4.0 Million MT Clinker & 5.0 Million MT Cement production.

Responsible of KPIs, Safety, Zero LTI & Environment and Emergency response implementation & achievement.

Planning from Quarry of Limestone till dispatch & supply of Finish Goods. CURRICULUM VITAE

Responsible of entire plant operation with conditioned based maintenance and considering the implementation & full compliance of the Plant Standard Operating Procedures.

Keeping an eye on the Quality of the Raw Materials & Products, maintaining strict limits to keep the best achievable uniformity. Plan, sketch, forecast day to day Production schedule based on Sales forecast & bi-annual production and refractory budget at rolling forecast basis.

Production / Operation / Maintenance / Manpower planning & recruitment as per market demand and operational requirements. Coordination with Sales & Maintenance team for Planned maintenance as per sales plan & market demand.

Follow up with CCR, Bag Packing, Bulk Loading, Dispatch & Logistic team, making stock planning as well as coordination with Sales team, logistic team & maintenance team as per market requirements, In charge of water treatment plant & managing day to day water requirements.

Discussion plan & uses of Alternative Raw Material with Quality head & Procurement Head for cost reduction.

Review daily production reports, assist for making Daily Production Reports, Stoppage analysis, Inspection checklist acquiescence, event-based planning and follow up, Chairing the RCA committee. Making monthly Summery report, Budget, Power & Fuel consumption, KPIs

& involvement in all reports for presentation to company Chairman & top management.

Day to day updates of erection, commissioning & PG test for Production line # 2 with supplier team & FL Smidth.

Overall responsible for 5.0 Million FL Smidth Plant, Two Clinker production line of 6000 TPD each Kiln, 2 VRM for raw materials, 3 Cement Grinding Vertical mills, 2 auto bag packers and 4 auto bag loaders. We achieved to dispatched 14,500 Tm in a day.

Highly awareness about customer satisfaction & complaints, Stick on Quality parameters as well as time management.

Worked with SAP for day to day operation

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Documentation of API approval for Oil Well Cement production as well producing OWC

Close contact with CCR staff & Shift in Charge for Fuel, Power & Heat efficiency.

Day to day Inventory management with Mines, Production & Warehouse team.

Set up & monitoring of self, staff & department appraisal Aug 2008 Till May 2014 LAFARGE Emirates Cement Fujairah, UAE Production Manager

Responsibilities:

Responsible for overall safety and Environmental issues any key responsible for Emergency response plan.

Responsible for plant operation considering the implementation & full compliance of the Plant Standard Operating Procedures. Keeping an eye on the quality of the product, maintain strict limits to keep the best achievable uniformity.

Plan, sketch, forecast the Production schedule & bi-annual production budget at rolling forecast basis.

Review daily production reports, Inspection checklist acquiescence, event- based planning and follow up

Responsible of Raw mill, kiln & cement mills operation, shutdowns execution & planning and post job evaluation.

In Charge for Utility & Water treatment plant

Annual & future planning for refractory works, anticipate the use of refractory & the cost saving from it by utilizing & introducing the new items, creating competent deals for the company

Communicate, document & report the daily shift operations and trouble shooting.

Help the shift Engineers, CRO & field staff analyze & react accordingly for the ongoing circumstances.

Ensure equipment safety & safe restart in case of emergency shutdowns. Preparation and checking of KPI’s on daily basis.

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Monthly / annually stock survey supervision and coordination with 3rd party.

Overall responsible for FL Smidth Denmark supplied Clinker Production Kiln of 7800 TPD, VRM for raw materials, 2 Cement grinding ball mills for 220 tph, 2 auto bag packers and 4 auto bag loaders.

Set up & monitoring of self, staff & department appraisal Achievements:

Initiated the creation & validation of SOPs.

Preparing monthly 30 reports dealing production & planning. Managing a team of highly skill professionals.

Analysis reporting and pre & post job analysis.

Closely worked with Geo-Cycle team for the project of alternative raw materials & fuels uses (Zinc Slag/ Cu Slag/ Sludge/used oil/tyre/pet coke) Achieved the 97.5% reliability for all major areas. Cost saving plan on industrial water, use of recycled grinding media, avoiding the refractory major repairs etc.

Key person in the OP-COM (Operations Committee).

Chairperson of the Kiln+ Coal mill Reliability Committee. Member of Kiln RCA team (Route Cause Analysis Team) Preparing & presenting the Monthly Performance of the plant in the EX- COM (Executive Committee).

Jan 2007 to Aug 2008 CEMEX, Cement Manufacturing & Ready Mix, Dubai-UAE Operations Supervisor

Responsibilities:

Erection, Commissioning & Optimization of LOESCHE Vertical grinding mill. Selection of the production team and give training about LOESCHE LM 56.3+3 of 210 tpd Clinker/Slag VRM.

Planning for erection & commissioning of Kiln & Raw mill after UAE market response.

Looking after whole plant operation and trouble shooting. Preventive maintenance breaks down & shutdown planning, budget planning and control.

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Raw material, fuel & inventory control, manpower planning and control, refractory plan.

In Charge for Dispatch, Utility & Water treatment plant Achievements:

Setup & Implemented the reporting system

Worked for JD Edward and set up for maintenance package Set-up of Fire alarm system with coordination of Civil defense. Commissioning of 2 heat generators & power generators. Set up & monitoring of self, staff & department appraisal May 1999 to Dec 2006 Ras Al Khaimah Cement Company, UAE Production Supervisor

Responsibilities:

Controlling activities individually with maintenance staff to look the entire Plant from LS Stacker/Reclaimer to cement dispatch. Involve in several modifications, trouble shootings, and performance guarantee test.

Refractory planning breaks down and shut down planning. Well knowledge of handling raw materials, physical stock measurement, manpower planning.

Commissioning, Operation & Optimization of 1 million ton per annum cement plant under the management of LAFARGE France. Involved in the successful commissioning of the plant from additive storage to cement dispatch to ship.

One operator is controlling whole plant.

Supervision refractory jobs during shutdowns. Control of Operation, maintenance and trouble shootings of Gas Turbine.

Involve in modification of Kiln Burner for duel firing system i.e., Gas as well as oil firing online change over.

In Charge of Water Treatment Plant, Gas Turbine & Utility. Set up & monitoring of self, staff & department appraisal May 1998 to Apr 1999 Raysut Cement Company, Salalah, Sultanate of Oman Process Officer

Responsibilities:

Commissioning and operation of 0.6 million tonnes per annum cement plant supplied by KHD Humboldt, Germany with Stacker, reclaimer, VRM by Pfeiffer 180 tph with classifier, only 36 meters long KHD kiln of 1800 tpd with alkali bypass (12%) and pyroclone online PC and heavy oil firing, 2 cement mills (ball mills) of 100 tph and control system by ABB – DCS. Involved in the successful commissioning of the whole KHD plant. CURRICULUM VITAE

Involved in Limestone crusher commissioning, manpower control, shut down planning, daily production reports.

Experience of Thermal oil heaters, ESPs, Bag house and Bag filters. Manpower control; break down activities, transport control, Shift schedule arrangement.

Involve in bypass system modification.

Dec 1994 to Apr 1994 Grasim Cement: An Aditya Birla group Raipur, India Asst. Process Engineer

Responsibilities:

Commissioning and operation of 1.8 million tonnes per annum cement plant with the following equipment

LOESCHE VRM of 330 tph.

FLS twin stream, 6-stage preheater kiln 3300 tpd capacity with SLC, Krupp Polysius – Polycom slag grinding roll press – 75 t Slag – OPC mixture machine

HAG for slag grinding and VRM

Online Gamma Matrix for Limestone stacking

LOESCHE Vertical Coal Mill – 50 tph.

DCS control by TATA Honeywell.

KHD Roll Press for clinker grinding of 320 TPH.

Involve in several modifications in Plant and DCS, got several appreciation letter and award from Grasim Cement.

Jan. 1990 to Dec. 1994 Modi Cement (Ambuja Eastern Cement) Raipur, India Asst. Plant Engineer

Responsibilities:

Involve in plant operation and process activities. Involve in making daily production/stoppage report. Coordinated with other department to make stoppage analysis. Operation of Krupp Polysius Plant, LS stacker & Reclaimer, Coal stacking and Reclaimer, 3300 TPD Polysius Kiln, 2 Polysius cement mills of 140 TPH 30 TPD Coal Mill, Polysius VRM of 270 TPH.

DCS system by CEGELEC – France.

Daily stock measurement & management.

Manpower management Shut down & break downs Activities. CURRICULUM VITAE

DATE OF BIRTH & PLACE

17

17-DEC-1963

SATNA-Madhya Pradesh-INDIA

EDUCATION

MBA from NIT Mumbai, India in year 2008.

Bachelor’s degree from Central University, Sagar, MP, INDIA in year 1988. OTHER CERTIFICATES & TRAININGS

Cement Plant operation & Cement Chemistry (from NCBM, Hyderabad, India) Safety & Fire Fighting, at Lafarge Emirates Cement, UAE Introduction & certification of ISO 9002, At Lafarge Ras Al Khaimah Cement UAE. Work at Height, First Aid & Rescue training, At Lafarge Emirates Cement, UAE Safety Induction at LAFARGE Emirates Cement UAE

Worked for ISO, IMS & API certification at Al Khalij Cement, Qatar. Problem Solving Skills- IBMI, Berlin-Germany

Bridging the Gap- BIM to Facilities Management- CPD, Qatar Daily Debate Panel- Importance of Equality, Diversity & Inclusion at workplace- CPD, Qatar Made SOP, MIS, ISO & API documentation in several Cement Plant Safety awareness program & Zero LTI as Lafarge standard, lead the Safety committee in Lafarge UAE

& Qatar

IT SKILLS

Advance user of MS Office (Word, Excel, Power point) Using the commercial mailing systems (Outlook & Lotus123) Using ERP system Oracle, JDE, SAP, Microsoft Dynamics 360 LANGUAGE

• English Fluent

• Arabic Basic

• Hindi Native

DRIVING LICENSE:

Having a valid driving license of Qatar, UAE & INDIA.

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