Mange Ram

Scaling new heights of success and leaving a mark of excellence in assignments which involve analytical capabilities and professional growth in Maintenance & Project department (Electrical and Instrumentation) Operations

adjgpl@r.postjobfree.com +91-766*******/829*******

mange.prajapat80@gmail,com

Key Impact Areas

Maintenance Operations

Total Quality Management

Strategic Planning & Implementation

Policies Formulation

Budgeting & Cost Control

Vendor Management

Resource Optimization

Spare Part Mgmt. (Procurement)

Training & Development

Certifications

1.Certified Internal Auditor for IMS

(ISO 9001, EMS 14001, OHSAS 18001).

2.Six Sigma Yellow Belt Certificate

3. PSP (Problem solving process) Blue Certificate.

4.Special training on troubleshooting in

Germany.

Project

Working as a project coordinator and recently

Completed one project on online data

Recording and monitoring system.

Profile Summary

Six sigma (yellow belt) and PSP Blue Certified Manager – (E&I) Maintenance, offering 15 years of national & international experience in manufacturing plant in implementing preventive maintenance schedules of various equipment to increase the equipment uptime / reliability & accomplishing project targets in continuous process/manufacturing plant.

Pivotal in steering the maintenance and troubleshooting of PLC & SCADA based machines (make ; Siemens), extruder section, Maintenance of hydraulic and pneumatic based machines, installation of new machines, Power distribution (Transformer, circuit breakers, LT panels, power factor correction unit etc.), Utility maintenance(Water cooled and Air cooled chillers, Air handling unit (AHU), Cooling towers, air compressor, DG set, Boiler etc), Field instruments (RTD, Thermocouples, Inductive sensors, Pressure Transducer, PID Controllers, VFD etc), Good exposures on energy saving and projects/CAPEX planning and execution.

Hands-on experience in implementing TPM and TQM concept in the process across the plant, Implementation of Kaizen, 5’S, QCC (Quality Control Circle) and Why-Why Analysis as well as ensuring compliance with ISO 9001, 14001 & 18001.

The wealth of expertise entails: Predictive, Preventive & Breakdown Maintenance, Always works towards “ZERO” breakdown, reduction in MTTR and improvement on MTBF Reporting & Documentation, Inventory Management, Erection & Commissioning, Installation & Troubleshooting, SOPs (Standard Operating Procedure) Formulation and so on.

Developed competency in establishing performance-driven culture that ensures personal ownership; led, guided, coached and motivated teams to achieve goals profitably.

Education

1).Diploma in Electronics Engineering from Govt. Polytechnic

College, Board of Technical Education, Rajasthan, in 2001.

2). B Tech in Electrical & Instrumentation engineering in 2005.

Organizational Experience

Tenure Organization Designation

Since Nov-2018 to Speciality Silica Pvt Ltd HOD - Maintenance

Till date Alwar (Rajasthan), Manufacturer of (Electrical and Instrumentation)

Spray dried silica in powder as well as

in granules form .

Tenure Organization Designation

Since Nov-2015 to Hussain Mohammed Abbas Maintenance Manager

Oct-2018 Block factory, Dubai (UAE) (Electrical & Mechanical)

Tenure Organization Designation

June 2010 to SRF Overseas Ltd, Dubai Maintenance In-charge

Nov 2015 Manufacturer of dipped (Electrical & Instrumentation)

Fabrics and Graige fabrics

(N6/N66/Polyester/Rayon)

Tenure Organization Designation

May 2006 to June 2010 Moser Baer India Ltd Maintenance Engineer

Manufacturer of data (Electrical & Mechanical)

Storage Devices (CD-R/DVD-R

JEWELL CASE/HD-DVD/CD-RW/DVD-RW)

Tenure Organization Designation

June 2005 to May 2006 Parasrampuria synthetics Ltd Assistant Engineer

Manufacturer of polyester (Electronics & Instrumentation)

Yarn (POY/LOY)

Technical Knowledge / Preview

Worked on PLC makes (Siemens, S7-200, 300 & 400), Window control centre (WINCC) operation and SCADA system make (Siemens).

Worked on pneumatic and hydraulic system (Cylinders, control valves, proportional valves, hydraulic power pack, and hydraulic servo drives etc.).

Worked on distributed control system (DCS) make: ABB, Taylor Mode-300 for controlling of level, pressure, flow and temperature of continuous process plant

Worked on A.C. and D.C. motor, Induction motor, Servo motor and different type of conveyors.

Working as a project coordinator and compiling existing/upcoming all major or small projects within the plant. Close coordination with all departments to complete the project within target date.

Experience in new machines and field instrument installation at macro level and completion of job within target date.

Planning of spare parts inventory, control over spare parts, repair and maintenance cost.

Preparation of MIS report and give the variance analysis for power, fuel and R&M cost and works towards to maintain all variable cost in the budget by taking corrective actions through proper analysis.

Planning of PM (preventive maintenance) every month & manpower planning for machine maintenance.

Having vast knowledge about different types of maintenance (Preventive, Predictive and break down maintenance) and always works towards ZERO BREAKDOWNS by implementing suitable corrective actions through route cause analysis.

Co-ordination with contractors, AMC vendors and service personnel for maintenance activities and new projects/modification in the existing machinery.

Preparation of R&M budget for Electrical & Instrumentation department and ensure to R&M cost within budget through systematic and close monitoring of daily maintenance management.

Created many SOPs (Standard Operating Procedure) for improving the uptime of machine.

Worked different types of A.C. and DC Drives make (Siemens, ABB, SEW,BARMEG, LDW, AEG, lenze etc.).

Worked on different type of temperature (PID) controllers make (taylor-500R, euro-therm, Chino, Toshiniwal, Masibus, ABB, Yokogawa, Honeywell, Radix, Foxboro etc.).

Good knowledge on different type of sensor, transmitter (pressure, flow and level transmitter), control valve, pneumatic & hydraulic valves and cylinders etc.

Worked on Power transformers (4 no’s) having capacity of 9 MW load (2.25 MW load each).

Worked on power control circuit (PCC), motor control circuit (MCC) and Air circuit breakers (ACB).

Worked on different type of material handling equipment’s (e.g. Hoist, fork-lift, power stacker etc).

Highlights

At Speciality Silica Pvt Ltd

SSPL is a continuous process chemical plant and manufacturer of spray dried silica in powder as well as in granular form having plant capacity of 7200 MT/Annum. The company certified with ISO 9001: 2015, which started its operation in the year 2006.

Unit contents of digester unit blow down tank, spray dryer, Reactor, hydraulic operated Filter press, Granulator, Suspension tank, Auto packing section, Silicate solution settling tanks, Coal gasification plant, Boiler, ETP section.

Ultra-modern plant having computerized process control (Make: Siemens).

Ensuring the utilization of man & machinery for attaining pre-set maintenance time

Crating new process concepts for maintenance optimization and yield improvement while developing guidelines for the sequencing of maintenance activities on the shop floor

Devising plans for daily, monthly and annual scheduled maintenance activities to achieve 100% of the target.

Leading, guiding & imparting training to the team for enhancing performance of the process

Performing up gradation, renovation & modifications in existing machinery & equipment for continuous improvement

Steering the maintenance of spare related procurement functions and performing vendor compilation participating in maintaining documents as per ISO Certification.

At Hussain Mohammed Abbas block factory,

Hussain Mohammed Abbas Block Factory is a local company certified with ISO 9001: 2015, Q Plus and DCL certification which started its operation in the year 1976. It is one of the oldest concrete blocks and interlocks manufacturing factory to cater to the ever growing needs of concrete products.

Unit is a fully automated and computerized concrete products manufacturing plant (Make: HESS, OMAG, made in Germany).

Unit contents different types of aggregate conveyors, Aggregate mixing plant, cement silo and screw, Block making machine and different types of product conveyors etc.

Engaged in managing maintenance related tasks which includes planning, control and troubleshooting for automated & computerized concrete products manufacturing plant (make - HESS & OMAG made in Germany)

At SRF Overseas Ltd,

Unit engaged in manufacturing of tyre cord fabrics.

Maintenance activities in the dipping machine. Make-beninger Zell, Germany (PLC and SCADA based machine)

Maintenance activities in twister machine (make- Saurer Allama, Germany) and Loom machine (make- Formiva Nuova, Italy and Sulzer, Switzerland).

Review the daily operating parameters of HVAC system by using BMS system.

Monthly Breakdown analysis report and over all power consumption analysis report.

Worked on :-

-TCS control system for better quality of product, by improving the roll winding to knife edge.

-Reduce the power consumption by modification’s, Kaizen and controlling of variable parameter’s such as chiller unit parameter’s Air handling unit optimisation, plant lighting load optimisation etc..

-Erection &commissioning of Digital Trio-canter and Full width spreader unit (width controlling device) in dipping machine for web spreading and edge controlling.

-Erection &commissioning of SADC system (make: Siemens) in dipping machine.

- Automated air handling unit (closed loop control system) for better control on Temperature and RH.

- Upgraded burner control system (PLC based) in dipping machine.

- Automated tension control system (closed loop control system) in dipping machine.

Operation& maintenance of HT circuit breaker, Power transformer (4 no’s 2.25 MW Load each).

At Moser Baer India Ltd,

Moser Baer is the world’s largest optical devices manufacturing company and manufacturing of Data storage devices such as CD-R/RW, DVD-R/RW, Jewell case etc.

Worked on shift as a shift in-charge and handling of daily machine break downs.

Worked in preventive maintenance team.

Worked on WIN-CC, Tool PC, SCADA & S7-300 SIEMENS PLC.

Worked in project team for converting CDR line in DVDR line with changes in hardware & software.

Teaching of Three axis and six axis Moto man and Denso Robots.

Attended problem in Servo Drives Teaching & Alignment, Sensors, Scanner and Sputtering process.

Uses different application of Servo Motors with fine Teaching and Alignment

Commissioning and installations work of CDR line.

Operation and maintenance of metallizer (sputtering section) and bonding section.

Maintenance of injection moulding machine (make: Sumittomo, Disc jet).

At Parasrampuria Synthetics Ltd,

Unit engaged in manufacturing of Polyester yarn (POY-10 lines & LOY-2 lines).

Worked in Electronics & Instrumentation Dep’t as an assistant engineer and responsible for break down reduction and preventive & predictive maintenance.

Worked on distributed control system (DCS) make: ABB, Taylor Mode-300.

Worked on DCS (4 nodes) for controlling of level, pressure and temperature of continuous process plant using transmitters (make Rosemount, Honeywell, foxbro etc.) control valves (mesonilan, Samson and valtec etc.).

Maintenance of high speed take-up winders (make Barmag, Neumag and Muratec) and spinning section and extruders.

Trainings Undertaken

TQM and 5 S training.

PSP (problem solving process) Training

ISO 9001, 14001 & 18001 training.

Training and certification for internal IMS audit.

Training on PLC system (Basics).

Training on maintenance and trouble shooting in Germany.

Personal Detail

Date of Birth: 25th June 1980

Nationality: Indian

Passport Details: Z3066470

Address: Flat no- 303, THD Garden (Trehan), Bhiwadi

District –Alwar (Rajasthan).

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