SANJAY MATHUR

***, *-* *****, **** PARK, Sector *5G, KHARGHAR, NAVI MUMBAI-410210

956*******, 965*******, adioua@r.postjobfree.com

EDUCATION/CERTIFICATION:

B.E (Chemical) from Shivaji University in1992.

IRCA Certified Lead Auditor & trained internal auditor for ISO 9001:2015

SUMMARY OF SKILLS:

- Strong command over Unit Operations, Process development and analytical ability.

- In depth understanding of KAIZEN, TPM, 5S, RCA & CAPA Implementation.

- Knowledge of ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018.

- Strong leadership, organizational and planning skills.

- Excellent communication and interpersonal skills.

- Ability to maintain compliance with critical safety and quality standards.

- Proficient in problem solving and time management skills.

- A believer in efficient man management by having good listening skills and compassionate approach.

CORE COMPETENCIES

~ Production Planning ~ Project planning & execution ~ Debottlenecking

~ EHS & HAZOP ~ Plant Maintenance ~ Process Improvement

Since April 2017 INDO AMINES LTD, Mahad AGM(Production)

Working as Plant Head for 2 plants engaged in the manufacturing of Fatty Amines & Specialty Chemicals in a Batch Process Plant.

Products Manufactured: BCFI(2Butyl,4chloro,5formylimidazole), PHPA(Parahydroxyphenylacetamide), PMPA(Paramethoxyphenylacetamide) & BetaPEAHCl.

Lead and monitor plant operations with a team of around 150 personnel in both units combined.

Planning, organizing, monitoring & guiding operations team to trigger corrective actions and resolve potential challenges likely to impact production, safety, quality or delivery schedules.

Initiation of Capex/Management of Change for Process Modifications and Expansion Projects which can benefit organization in terms of production, quality, safety and environment.

Conduct daily meetings with HODs of Production, Quality & Maintenance to resolve plant issues.

Implementation of policy decisions & initiatives for improvement in Productivity, Assets Utilization, Cost Control and Quality standards in coordination with Cross Functional Heads.

Responsible for managing day to day operations including Planning, scheduling, purchase, HR issues etc.

Control over equipment breakdowns by timely preventive and predictive maintenance schedules.

Preparation of budget and finalize material and labor requirements as per production goals.

Analysis of Product material balances, Monthly Batch time cycles & Equipment idle hours with appropriate RCA and CAPA implementation.

Ensure compliance of regulatory requirements for Environment, Safety and Pollution by structured monitoring of EHSQ performance.

Ensure that the plant housekeeping and safety is maintained as per 5S and GMP norms and comply with findings of safety and housekeeping committee audits conducted on quarterly basis.

Development of R&D products on commercial scale after successful pilot plant trials.

Imparting training programs to all employees after assessing their skill and gap analysis.

Reactions/Unit Operations: Vilsmeier Reaction, High Vacuum Distillation, Hydrolysis, Filtration,Drying.

Equipments handled: MSGLR, Autoclaves, Centrifuges, Distillation Columns, HCl scrubbing columns, High vacuum ejector systems, RVDs and Tray Driers.

Accomplishments:

Successful Erection and Commissioning of BCFI Project.

Development of new products such as BetaPEAHCl & PHPA on commercial scale.

Increase in 5% Production Capacity of BCFI year on year by implementation of KAIZEN and process debottlenecking.

Implemented Plant Safety Program with quarterly safety audits and encouraging near miss reporting, resulting in 50% reduction of recordable injuries.

April 2014 to March 2017 ROHA DYECHEM PVT LTD, ROHA, Distt.Raigad Production Manager

(A JJT Group Company - Batch Process Plant)

Worked as Production Head for manufacturing of Basic & Lake Color Dyes for food industry and

Copper Phthalocyanine blue and other pigment grades.

Managing a team of more than 120 personnel to achieve monthly production targets with compliance of Safety, Quality and GMP requirements.

Production planning and control for batches charged in line with SOPs and with minimum deviations.

Execute Pilot Plant trials of new products/processes and scale up on plant level for commercial runs.

Compliance of GMP Norms with RCA and CAPA for any violation observed during site rounds.

Handling of Process modifications & debottlenecking projects to enhance productivity.

Independent handling of erection &commissioning of plant expansion project undertaken for augmenting capacity of Basic and lake color dyes such as Tartrazine, Quinoline yellow, Allura red etc.

Periodic safety audits & quarterly safety and housekeeping committee meetings to check for unsafe working practices and take appropriate corrective action.

Managing with external agencies such as MPCB for meeting treated wastewater norms.

Reactions/Operations: Diazotization and Coupling Reactions, Filtration, Drying & Milling operations.

Equipments Handled: MSGL and MSRL Reaction Vessels, Filter Presses, NF membranes, Driers such as Spray Driers, RVD, FBD, Spin Flash Driers, Vibratory sifters, ANF etc.

Accomplishment:

Production Capacity Enhancement for Basic Color Dyes by 10-15%:

- Increase in optimum batch charging capacity by eliminating freshwater intake for direct cooling and

opting for external cooling.

- Spray Drying Cycle time reduction by step wise conversion of normal recess plates to membrane

plates in filter presses thus ensuring better squeezing and reduced moisture content.

ETP load reduction of 10% by

a) Recycling of last stage of Mother Liquor from filter presses for use in fresh batches.

b) Water saving in cake washings by throttling of filtrate cocks and increasing retention times.

Recycling of leaked product from filter presses (due to cloth damages) into an ANF for recovery of lost product. Additional yield of 2.5% achieved.

Reduction in ONT solvent consumption norms from 85kg to 74kg/MT of CPC Blue pigment product:

-Installation of additional settling tank for solvent recovery.

-Periodic cleaning of PHE to reduce solvent losses.

-Timely recovery of solvent from inlet trough of collection tank.

Nov 2003 to April 2014 ORIENTAL CARBON AND CHEMICALS LTD, Haryana Sr. Manager (Prod.)

(JP GOENKA DUNCANS Group Company)

100% EOU Insoluble Sulfur Continuous Process, DCS Operated Plant)

Worked as Production Incharge for 100% EOU Insoluble Sulfur Manufacturing Unit.

Develop and execute production plan based on the demand from the marketing department.

Maximize effectiveness of production team, equipment and materials to produce multi grade products

within planned schedules in a SAP Controlled Process Unit .

Process Improvement Activities like KAIZEN, CAPA, 5S and ROOT CAUSE ANALYSIS for identifying deviations and complying with plant KPIs.

Working as MR for ISO 9001:2008 & ISO 14001: 2004.

Implementation of Water conservation measures:

- Reuse of reactor jacket & process drain for cooling tower makeup

- Recycle of STP water for toilet flushing & gardening applications & treated ETP water for CS2 dykes.

MIS Reports:

- Corrective and Preventive Action Reports

- Actual v/s Planned production

Conducting HAZOP for critical chemical operations and SPC studies for process performance.

Process time cycle monitoring for root cause analysis & suitable corrective action.

Unit Operations handled: Melting & Polymerization of raw sulfur, drying, solvent extraction & distillation.

Mechanical Operations: Pneumatic Conveying, Blending of Naphthenic Oil with insoluble sulfur, Grinding of insoluble sulfur using hammer & roller mills.

Equipment handled : Band Dryer, Nauta Mixer, Pneumatic Conveying, Packed distillation column, SS316 hoppers & storage tanks, Canned Pumps for CS2 handling, Blenders, Roller & Hammer Mills & vacuum pumps.

Accomplishment:

Improved productivity by 10 -12%.

Erection and Commissioning of PILOT PLANT for sulfur vapor quenching in carbon disulfide.

Successfully installed & commissioned a fume extraction unit to exhaust toxic sulfur fumes from the plant area.

Aug 1994 to Nov 2003 INDIA PESTICIDES LTD, Lucknow Asst. Manager (Prod)

(Batch Process Plant for pesticide manufacturing)

Managing shifts to oversee production in Monocrotophos (Tech) & DDVP (Tech) plants.

Accountable for production, maintenance, process control & waste minimization.

Improve process efficiency with respect to solvent recovery and waste minimization.

Erection & Commissioning of Monocrotophos (Technical Grade) pesticide plant.

- Preparation of P&Ids and PFDs for plant & utility equipment.

- Sizing and design of process and utility piping.

Unit Operations handled: Exothermic Chlorination Reactions, Filtration, Vacuum distillation & Evaporation Equipment handled: MSGLReactors, Chlorine vaporizer, Graphite Block type heat exchanger, Agitated Nutsche Filter, Agitated Thin Film Evaporator, and Steam jet ejectors etc.

Accomplishment:

Higher productivity of Monocrotophos (Tech) – from 2.5TPD to 3 TPD

Jan 1993 to July 1994 DHANUKA PESTICIDES LTD, Sohna Asst. Chemical Engineer

(Batch Process Plant for pesticide manufacturing)

Production handling in shifts for manufacturing of pesticides like Cypermethrin & Fenvelerate.

Worked for installation & commissioning of chemical incineration unit.

Routine Maintenance & other plant fabrication jobs for trouble free production.

Preparation of PFDs/P&Ids for plant expansion projects.

Unit operations handled: Exothermic chemical reactions, azeotropic vacuum distillation & filtration.

Equipment handled: MSGL Reactors, Distillation columns, Steam & water jet ejectors, centrifugal pumps.

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