Plant Mechanical Engineer

Hemendra Waghela

Baytown, TX ***** +1-936-***-****

***************@*****.***

Plant Maintenance Manager

Driving profitable, reliable, and safe production facility through strategic maintenance practices, planning, execution, and operation.

Goal-driven, safety-focused Mechanical Engineer by profession with diverse functional skillset, strong technical aptitude, and outstanding attention to detail. Over 15 years in management and optimization of high speed & high volume manufacturing facilities like steel rolling, steel forming & steel making processes . Deep knowledge of plant construction, new facility set up, setting up automation processes, thereafter maintenance & operations of plant, field projects, continuous improvement projects, CAPEX, OPEX and production performance . Drive improvement in plant operations, Setting up CMMS program, Maintain CMMS maintenance systems, TPM systems, Lean manufacturing, process safety, and reliability programs; engineer initiatives that reduce risk, increase reliability, and reduce costs & control maintenance budgets . Promote cross-functional collaboration between teams, management, and outside partnerships.

Highlights of Expertise

Manufacturing & Plant Operations

Commissioning & Turnaround Management

Site Construction & Materials Management

Preventative Maintenance of plant assets

Strategic Planning / Data Collection & Analysis

Risk Management, Safety & Compliance

CMMS systems – creation, monitor & control

Total Productive Maintenance (TPM)

Static / Rotating Machinery Installation

Budget Administration & Cost Control

Full Lifecycle Project Management

Contract Management / Vendor Relations

Process Improvement / Quality Assurance

Staff Training & Development / Leadership

ERP systems - SAP & IQMS

Lean Manufacturing

Career Experience

Boomerang Tubes, LLC, Liberty, TX, USA 8/2013 to 6/2020

PLANT ENGINEERING & MAINTENANCE MANAGER

Provide daily technical support and leadership to drive maintenance & plant engineering needs to high speed OCTG steel pipe manufacturing facility (300K Ton capacity ) content of static & rotating heavy plant machineries, automation system, several hydraulic power units, lubrication systems, air systems and pneumatic control systems, water cooling towers & pumping systems, HVAC systems, PLC, motors, drives, plant captive power plant, plant piping, buildings & out door facilities .

Build effective teams and direct training of technical personnel which includes plant engineers & maintenance supervisors ; provide 24/7 guidance to plant shop floor team & initiate continuous improvement projects / maintain plant facilities -indoor & out door, create maintenance and CAPEX budgets. Plan and execute green and/or brown field projects; evaluate site operational, maintenance, and/or reliability issues; manage & monitor the materials and parts consumption pattern and reduce the cost. Work with parts store team, order & maintained desired quality & quantity and specified parts .

Coordinate with the Plant Manager / plant management team and attend daily/weekly/monthly performance meetings . Based on going issues, develop and implement solutions . Conduct site safety audits and enforce compliance.

After completion of project, Taking care of daily plant safety & personnel safety by enforcing the safety policies, safety audits & weekly safety meetings

Create KPIs for team mates based on annual business plan, this includes day to day activities to support the plant, improvement projects, automation projects, yearly /monthly / weekly shutdown plans

Co-ordinate with customer, end users, vendors, contractors, plant management team to accomplish the task

Creating daily inspection work orders, preventive work orders, maintain CMMS system, work order systems based on end user maintenance requests, plant walk through observations, inspection walk through observations

Coordinate with plant engineers, supervisors, technician & contractors to complete the open work orders and direct them to accomplish the task as planned / scheduled .

Order the material for work orders & plan the jobs, maintain inventory

Create maintenance plans & turnaround planning, coordinate with project & engineering team

Schedule the work orders after availability of PARTS & manpower and downtime whenever it is possible

Priority decision based on task emergencies, production needs & cost control for safe operations

Create material purchase requisition & follow up with purchasing agent / vendor for timely delivery

Analyze the failure & develop the solution after brain storming with plant team

Develop continuous improvement initiative & CAPEX / OPEX projects

Work with project /engineering team & take lead to complete the task . Responsible to complete new projects with help on inhouse or outside team

Create Yearly budget, monitor the cost monthly & present the reports . Find the solution if any variance between actual & Target numbers .

Attend daily / weekly / monthly performance meeting, create & work towards discussed strategies . Create department performance reports / presentation for monthly meeting .

Reduce operational costs through control of parts wastage and maintenance expenses; improved plant efficiencies and removed multiple bottlenecks.

Leverage plant technician knowledge and talent for troubleshooting to resolve technical issues; investigate and determine root causes and implement solutions in a timely manner.

Apply concepts of total productive maintenance (TPM) to advance integrity of production, safety, and quality; set up equipment, procedures, and computerized maintenance management systems (CMMS).

Introduced world class management practices in engineering, maintenance, materials, human resources and more; converted plant facility into profitable unit.

Welspun, Anjar, India 4/2006 - 8/2013

MANAGER – PLANT PROJECTS, ENGINEERING & MAINTENANCE

Assisted with build of $1B steel plate and coil, steel billets & TMT bar production facility ( 1 million ton capacity ) with primary focus on plant operations, asset management, plant & personnel safety and training to build the technician / supervisor team.

Assisted in conducting plant feasibility study and bid review; prepared project budgets and schedules with report to upper management. Managed contracts, reporting, and documentation (e.g. bill of materials, tenders, estimates, etc.). Monitored performance and resolved technical issues during construction of the plant .

Lead the plant installation activity which includes machine foundation, machine anchoring & alignment, electrical & utility connections, quality checks at every stage, sign off the project protocols, works with plant project team, correct the issue or inform concerned for timely action, monitor the site progress, train technician team, maintain the documentation, preserve drawings

Created brand new SAP based CMMS systems ( PM Module), entered appropriate data to develop CMMS systems .

There after worked towards developing the plant maintenance department which involves creating systems, JSA, SOPs, Asset management plan, creating corrective / preventative / predictive maintenance plans and repairs of equipment as per CMMS work orders .

Associated with day to day plant maintenance need like inspection of static & rotating plant machinery, challenges, quality systems, product quality, material management, maintenance team to achieve the monthly / yearly targets .

Managed day-to-day operation and maintenance with help of technician team ; coach / mentor /train team on new systems & wherever there are issue, work with team till resolve issues after monitor the progress . Maintain the logs & create historical data in CMMS system, analyze for the data

Manage parts & inventory as per maintenance plan, control inventory but same time maintain critical spares

Maintain CMMS system, review maintenance requests, plan the jobs, schedule the activities, arrange resources ( internal / contract )

Maintain Utilities systems, manage per ton electricity and maintenance cost as per budget, report wherever discrepancies arise, resolve issues by analyzing the issue . Detailed oriented where ever required by process .

Analyzed production data and developed strategy to fill variance between actual and targeted results and brought operation into profit; maximized capacity while minimizing costs.

Monitored daily progress of build; conducted quality checks and safety inspections and took corrective action as required to safeguard personnel and integrity of construction.

Controlled design, drawing, and documentation; finalized plant layout, specifications, and technology selections; and developed manufacturing, maintenance, and quality management systems.

Jindal US Denro Steel, Baytown, Texas. 3/1998 - 3/2006

MANGER – ENGINEERING & MAINTENANCE

Led site personnel in the restart of US steel hot rolled wide plate rolling manufacturing facility ( 1 million ton per year) . Managed plant operations and maintenance post-commissioning with a staff over 25 direct employees ; recruited, trained, and led production team. Oversaw project feasibility study, layout and plant building engineering, finalizing of technology, and document creation and control. Sourced and selected vendors, managed contracts, developed project budgets, scheduling, and quality controls.

Overhauled machinery, hydraulic systems, and repaired utilities including natural gas furnaces, water pumps, cooling towers, pneumatic systems and air compressors with zero time lost from injury.

Directed design of piping, controls system, instrumentation, P&I diagram, power sub-station, power distribution, equipment and machinery foundation, erection, and set up.

Optimized plant capacity and efficiencies while maintaining low overhead with development of top-level manufacturing and maintenance system.

Manage & maintained the CMMS system, plan all jobs through systems, control budgets, captured task costs through systems

Education & Credentials

Associate Degree Mechanical Engineering Govt Polytechnic, Pune, INDIA

BSc in Mechanical Engineering National Institute of Technology (NIT), Nagpur, India

REFERENCES

AVAILABLE ON REQUEST

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