Plant Manager / Mechanical Maintenance / Technical Manager

S.PURUSHOTHAMAN

Mobile: +255-***-***-***; +91-763*-******~ E-Mail: adg2hg@r.postjobfree.com

Professional Synopsis

A competent professional with over 19+ years of experience in various Cement Plants in the key areas of New Projects, Process Enhancement, Commissioning, Operations and Maintenance.

Presently associated with Kisarawe Cement Co Limited, Kisarawe, Dar Es Salaam Tanzania as Plant Manager.

Expertise in implementing cost saving measures to achieve substantial reduction in terms of man days, production cost, raw materials, etc. Skilled in implementing effective techniques to bring efficiency in operations to improve quality standards & achieve maximum cost savings.

Possess sound knowledge of planning, scheduling & quality control functions in Cement Plant.

Comprehensive understanding of diverse regulations & commercial affairs.

Comfortable interacting with multiple levels of organization, management and staff. Effective communicator with strong analytical, problem solving & organizational abilities.

Skill Set

Project Coordination

Participating in planning and scheduling site activities to ensure completion of the project within the time and budgetary parameters and for optimizing resource utilization.

Managing the site activities including planning and assigning manpower resources & tools; providing external and internal timely and accurate professional reports.

Analysing various processes/ applications and recommending process modifications and equipment calibrations to enhance operational efficiency. Identifying project bottlenecks and undertaking corrective measures.

Process Enhancement

Identifying scope for Planning, implementing & monitoring of technological changes to enhance productivity; modifications in equipment, process flow, working practices, consumables, power, etc. for controlling & reducing conversion cost per unit produced.

Executing cost saving techniques / measures and modifications to achieve substantial reduction in O&M expenditures and work within the budget. Leading operations/ production team for cost effective production & providing guidance for technical trouble shooting of process & plant.

Installation and Commissioning

Managing overall activities pertaining to erection & commissioning of plant equipment

Conducting inspection, pre-commissioning & functional testing to ensure the performance capacity of all the machines and equipment. Supervising commissioning activities in adherence to the companys standards and specifications.

Maintenance and Troubleshooting

Planning and effecting preventive maintenance schedules of various machineries and instruments to increase machine uptime and equipment reliability; executing cost saving and energy saving techniques/measures and modifications to achieve substantial reduction in O&M Expenditures and work within the budget.

Effectuating predictive, preventive & breakdown maintenance schedules of plant assets; conducting periodic checks to ensure performance of various equipment and maintaining requisite documents for the same

Attending third party audits; preparing various project reports for identifying areas of obstruction / defects, conducting troubleshooting, service and repair to rectify the equipment.

Safety Management

Creating effective procedures for the preparation and implementation of programs within the area of safety, and the environment in process.

Conducting Safety Internal Audits & Risk Assessment; implementing Health Safety Environment Management System and formulating First Aid Scheme.

Imparting training to employees & handling through work permits.

Advising employers / employees on safe & healthy work practices & health / safety management systems.

Team Management

Leading, mentoring & monitoring the performance of Engineering Team to ensure efficiency in process operations and meeting of project targets.

Creating and sustaining a dynamic environment that fosters development opportunities and motivates high performance amongst team members.

Work Experience

Sep 15 Till date Kisarawe Cement company Limited Dar Es Salaam, Tanzania

Accountabilities:

Responsible for:

Cement Plant O&M

Quality systems and maintenance

Plant budgeting and planning

New project EPC and execution

Employees engagement and their appraisals

Safety of plant premises and all personnel

Profitability of the plant operation

Planning and execution of rules, regulations and procedures

Dealing with local bodies like TRA, TBS., for plant operational and quality issues

Jan 14 Jun 15 Sun Engineering Ennore, Chennai

Accountabilities:

Responsible for:

Making the quotations to the optimized level of expenses

Budgeting and planning

Manpower planning and arrangements

Project scheduling and execution to meet the customer satisfaction

Employees welfare at site location

May 13 Jan 14 Zuari Cement Limited Athipattu, Chennai

Accountabilities:

Responsible for Plant mechanical maintenance activities

Responsible O&M of plant

Responsible for safety implementation in O&M as per the group policy

Responsible for Maintenance budgeting and spare controlling

Nov00 May 13 Ultra Tech Cement Limited Birla White, Jodhpur, RJ

Accountabilities:

As Project execution Section In-charge (Jun 12 Till date ), Birla White, Jodhpur, Rajastan.

Responsible for execution of the ongoing projects such as enhancement projects

Plant up gradation projects

As Cement mill Operation & Maintenance Section In-charge (Dec07 Jun 12), Koppal, Karnataka.

Ensuring that the plant is in Ready-to-Start position; providing guidance to the supervisors on planning and executing the job.

Carrying out manpower planning for the operation & maintenance; organizing meetings with the contractors & supervisors for achieving the targets.

Implementing the IMS system in packing plant section.

Administering the erection and commissioning of VRM (LM53.3+3C) with classifier, various types of conveyors (BB/E,DPC, Chain elevators, Stacker and Re-claimer, RBCs & air slides),

Entire Packing plant equipments (6RSE, PM, TLM& allied equipments), Weigh Feeders& SFFs and Multi-Compartment Silos.

As AET Leader (Jun04 Dec07),

Held the responsibility of the PACT (Process Area Care Team) leader for Packing Plant.

Looked after standards preparation & segregation for the PAC teams of CPP & utilities.

Administered functions entailing to manpower reduction & effective utilization of manpower in our area.

Prepared the MIS report for monthly presentations; mapped the project, developed road map.

Handled the DMAIC projects preparation & implementation with PACT members

As PAPC Supervisor (Nov00 Dec07), Vellore

Looked after the maintenance of Packing Plant & Allied Equipment.

Managed the maintenance of all the equipment through PM, Scheduled maintenance and daily check lists.

Carried out plant maintenance through preventive, stoppage maintenance and scheduled maintenance.

Major Highlights:

Implemented HAG operational procedure as different from the suppliers procedures.

Brought 35% reduction in breakdowns / downtime through effective maintenance.

Examples of troubleshooting or problem solving exercise undertaken:

The truck loading manpower reduced by Engineering and implementation of truck loading machine from 90% of scrap.

The failed Fly ash handling system was made as a successful system through brainstorming and DMAIC technique.

The water consumption for Cement grinding was reduced from 3.7 cu.m to 1.5 cu.m.

The packed cement bags damage was drastically reduced from avg. of 76 bags/ day to 8 bags/ day within the span of 03 months, etc.

Resolved major technical issues like:

The Metal diversion due to metal contents in slag was reduced by vibrator screen system during the slag unloading.

HFO consumption in HAG for grinding cement drying process was reduced from 10.6 l/ton of grnd to 6.13 l/ ton of grnd.

A defective multi compartment silo, has been successfully repaired as a single headed and running without any problem.

Packing unit was started without the Cement Silo as a single headed design, erected and commissioned before the committed date, etc.

Project Details:

PROJECT: 1

Title: UltraTech Cement Limited, ARCW

Description: A 1.3 MTPA plant with ball mill erection and commissioning

Duration: 9 months

Role: Project Erection Supervisor

Team Size: 193

PROJECT: 2

Title: UltraTech Cement Limited, GiCW

Description: A VRM (LM53.3+3LKS) based 1.5 MTPA plant project commissioned

Duration: 12 months

Role: Project Mechanical section In-charge

Team Size: 135

PROJECT: 3

Title: UltraTech Cement Limited, BIRLA WHITE, Jothpur

Description: A chalk handling unit of 2 kms EPC and commissioned Clinker Dust handling system from kiln (1&2) EPC done crusher plant of 175tph EPC done and commissioned from the scrap

Duration: 9 months

Role: EPC section Engineer

Team Size: 179

Successfully held the following responsibilities:

Safety Trainer : Certified Train the trainer for the group of unit representatives

Safety Committee : Safety Standards and procedures preparation committee for entire Cement group of ABG (Confined Space)

Safety Standard Implementation : The safety standards (GWP, LOTO, CSE, W@H, Scaffolding, Lifting & lowering) implementation coordinator for the business unit of ABG.

World Class Manufacturing : Facilitation in achieving Global standards in manufacturing.

Internal Auditor : Internal Consultant for improvement initiatives, Internal Auditor of Safety issues.

SAP PM, PP and MM Module : Facilitating SAP PM Module implementation such as Equipment database, maintenance task list, etc., and new codes creation for equipment spares.

Edification

Diploma in Mechanical Engineering Murugappa PolyTechnic (BTE), Chennai, TN 1998 68.17%

Trainings Attended

IMS (QEOHSS) conducted by DNV, Hyderabad.

Safety & Fire Classes by KARAM and L&T.

Communication & Presentation Skills Development by IHRD, Bangalore.

Supervisory Development Training by IHRD, Bangalore.

Team Building Training by PPS, Chennai.

Advanced Maintenance Techniques by L&T and SKF.

Performance Management Skills by ABG Training Cell.

Personal Dossier

Date of Birth : 21st January, 1980

Present Address : #79 Lake View Street, Thandalam Village, Kumpinipet Post, Arakkonam Taluk,

Vellore District 631003, Tamil Nadu

Passport No : N1401361 (Valid Till 16th July, 2025)

Linguistic Ability : English, Tamil, Telugu, Kannada and Hindi

Contact this candidate