Cement Plant Manager/Production ManagCommissioning Manager

Engr. Saeed Ahmad

B.Sc. Chemical Engineering (Punjab University, Lahore, Pakistan)

Personal Info: Resident: Wah Cant. PAKISTAN

E-mail ID: ****.*********@*****.*** ; **************@*******.***

Skype ID: engr.saeed2764

Mobile NOs: +92-300*******, +92-312*******

Summary:

27 years’ experience in field of Cement plants, worked as Manager Production (HOD), QC& Dy Plant Manager having key skills of Cement Plants; from Initial stage to final stage, from documentation to final contract, From green field to Brown field Plant, rebuild Plant, erection, commissioning, Trouble shooting, Cost Reduction, optimization, usage of alternative fuels (RDF, Tyres, wheat straw, poultry waste, rice husk) and smooth operation of Plant. Commissioning Manager of Greenfield Cement Plant, Captive Power Plant and Water treatment Plants. Certifications of SASO,PME & IMS of ISO 9001-2015 &14001-2015,18001

Profile:

Consultant-Cement Industry: From August, 2018 to till date. TeamUp Advisory, National Incubation Centre Islamabad.

Achievements:

Fauji Foundation Project (Fauji Cement and Askari Cement)

Integration of Management, Optimization and Cost reduction (Rs.200 Million per annum).

Validation of expansion projects, Green field Cement Projects.

EXCOM meetings,

Validation of New Cement Plants expansion.

Review of Alternative fuels utilization and renewable Energy Projects.

HSE guidelines.

Potential Savings, implementation and evaluation.

Manager Production (HOD), QC& Dy Project/Plant Manager: From April, 2015 to June, 2018, United Cement Industrial Company, SAUDI ARABIA.

Integrated Cement plant of capacity 2.0 million tons per annum.

HOD Process/Production.

Acting Plant Manager.

QC Manager

Commissioning Manager during commissioning from Crusher to Packing Plant, Power Plant and Water Treatment Plant.

Refractory Management

HSE Certification and target Zero Accident.

Achievements:

Completion of Project within time frame and achieved budgeted target of Clinker and Cement.

The most economical Cement Plant of Kingdom of Saudi Arabia.

Overall commissioning of Cement Plant from Crusher to Packing Plant, Captive power Plant of capacity 55 MW from MAN, Germany and Water Treatment Plants.

Plant taken over from Sinoma after guarantee/warranty

Budget preparation and utilization.

Manpower hiring and training of local Saudis

Management meetings with consultant, Suppliers (MAN & Sinoma) and with VPO &CEO.

Optimization of Water Consumption.

Environment, Safety and quality management standards Certifications PME &SASO, ISO 9001-2015 &14001-2015,18001

Clinker Production increased from 5000 TPD to 5600 TPD

Certifications on Project Management, Time Management,Employees engagement from Knowledge City USA

DGM (Production): November, 2014 –March, 2015, Pioneer Cement Ltd Pakistan

Managed integrated Cement plant of capacity 2.0 million tons of FLS make.

Production activities from crusher to packing plant, trouble shooting of process problems and coordinating maintenance activities with mechanical, electrical departments for

annual and planned stoppages

Coordination of production monthly review meeting, cost bench marking, comparing cost saving parameters, and monitoring KPIs

Managed work force of 100 staff; Production Engineers, CCR Operators, Technicians.

Achievements:

Erection, Installation and commissioning of latest technology FONS Delta Cooler.

Feasibility of WHRP and different up gradation projects including new line.

Reduction of dust flushing(300 TPD to 25 TPD) from off-line Pre-Calciner

HOD (Production) May, 2010-October - 2014, Bestway Cement Ltd. PAKISTAN,

Cement plant of capacity 1.2 million tons of MHI/FLS make.

Production activities from crusher to packing plant, troubleshooting of process problems and coordinating maintenance activities with Mechanical, Electrical departments for annual and planned stoppages

Coordination of production monthly review meeting, cost bench marking, comparison of cost saving parameters, and monitoring of KPIs

Managed work force of 60staff; Production Engineers, CCR Operators, Technicians, Patrollers, Refractory management.

Conducted feasibility study and implementation of alternative fuels’ usage

Head of HSE committee.

Conducting of training/dialogue session with departmental staff regularly

Achievements:

Enhancement of Clinker Production Level from 3850 TPD to 4050 TPD.

Reduction of Heat Consumption from 780 Kcal/kg Clinker to 765 Kcal/Kg Clinker.

Optimization of Raw Mill and Cement Mill

Trainings Abroad:

Seminar and training on Refractory Technology, application, installation and associated Cement process problems, from September 01, 2013~September 13, 2013 arranged by M/S Refratechnik GERMANY.

Process Expert: Jan.2009-March, 2010, Lafarge Cement, Indonesia.

Rebuilding of Production line, having Capacity 6000-TPD.

Commissioning, erection, trouble shooting and operation of the plant

Production management and identifying deviation in operation and discussion with Plant Head for streamlining

Functional analysis of Plant; its sequences and interlocking

Reviewing day-to-day plant performance, its achievement and problems faced during the day; preparing production report, plant performance report and materials stock report.

Safety aspect of plant site, information collection and diagnosis, providing guidelines to staff for safe practice during trouble shooting activities.

Identify, review and issue instructions to implement equipment’s safety interlocking.

Champion for Alternative Fuels.

Total refractory management

Coordinator commissioning team from Crusher to Packing Plant.

Evaluating plant-operating conditions by referring to critical operating parameters.

Critical problem areas/equipment inspection

Trainings & Seminars Attended during my stay with Lafarge Cement Group, Indonesia

OPG Preparations Training, Lafarge Indonesia.

LOTOTO Training, Lafarge Indonesia

Special training program on CECIL and ATC Programs.

POMS Training.

Training on Heat Balance, Mass balance, Gas handling arranged by ATC(Asia Technical Centre Malaysia)

Training on Pyro-Processing arranged by ATC (Asia Technical Centre Malaysia)

Refractory Training arranged by ATC

VFL training PT.SAI Indonesia

Coaching skills workshop :

1. To align people development to business performance

2. To fully understand management role in the development of employees

3. Understanding of Cement Professional Development Program (CPDP)

Cementitious training by ATC (Asia Technical Centre, Malaysia) to produce good Quality Cement

Senior Dy. Manager Production: June, 2006-Aug, 2008, Fauji Cement Company, Pakistan

(3700-tpd ILC plus 5 Stage FLS Cement Plant).

Monitoring of KPI of Kiln CM and RM

Analyzing of Check lists.

Reviewing pervious day plant performance, production achieved and problems faced and prepare/reviews and coordination with planned maintenance team.

Safety inspection of plant site, information collection and diagnosis g, preparing guidelines and caution for safe practice for personals

Personally monitoring of current operating conditions, production and quality levels provide necessary guidance/targets to kiln/mills operators and field operators.

Identify, review and issue instruction to Instrument/PLC staff to implement process/equipment & safety interlocking.

All production reports preparation, correspondence with vendors, government agencies/departments

Annual Staff performance evaluation; Staff motivation, Performance management and appraisals

Prepare specifications, raise indents, and evaluate offers and inspection of materials received

Refractory work performance evaluation and relining plans

Ball mill grinding media wear rate estimate, charge evaluation.

To hold/attend special task/project meeting

1.Participated in selection of new line of 7200TPD.capacity

2.In charge of MIS & ERP system documentations and implementations; acted as Safety, Environmental & Health Engineer within the production department

Trainings attended during my stay with Fauji Cement Limited, Pakistan

Certificate of Management training course on Negotiation Skills by Pakistan Institute of Management. Lahore.

Certificate of Two-days Seminar on Grinding Circuits, Ball Mills, Vertical Mills, Separators, Mill internals, Grinding Media, Hammers, Cooler plates, Immersion tubes, Wear & Abrasion Resistant materials in Cement Industry arranged by Magataux

Senior Dy. Manager Production: October, 2004-June 2006, Lucky Cement Ltd, Pakistan.

Erection and Commissioned lines C &D projects having Clinker capacity 3300-TPD each, ILC 5 Stage Preheated with IKN Pendulum Cooler from M/S Hefei, CHINA

Refractory supervision kiln, pre-heater &IKN Cooler.

Preparation of operating sequences of whole plant with the cooperation of ABB &Hefei Automation, Germany & China respectively

Troubleshooting during commissioning;

Assistant Manager Production: Sept.1996-Sept.2004,

Army welfare Trust Nizampur Cement Plant, Pakistan.

(4000 TPD from TCDRI China, 5 Stage double strings ILC Cement Plant with Grate Cooler).

Worked as Officiating Manager Production.

Plant commissioning and operation

Worked as Assistant Production Manager /QC/Kiln in charge/Cement Mill In charge

Internal Auditing Techniques QMS/EMS ISO 9001:2000&ISO 14001:2004

Advanced Cement Technology Certification Training from TCDRI China

Three-months Advanced Cement technology training from TCDRI, CHINA.

Assistant Manager Production: June, 1993-August, 1996, Kohat Cement Company, Pakistan.

Commissioning of XRF and carried out Chemical/Gravimetric chemical analysis of Cement, Clinker and raw materials.

Kiln and Cement Mill operation and Shift Engineer.

Kiln In charge, assistant Manager Production.

References:

1. Mr. Salah Uddin Ali- Chief General Manager - Dangote Cement Group

Cell No. +92-334*******

2. Mr. Sohaib Ahsan- GM (works) - DG Cement, Kallar Kahar, Chakwal, Pakistan

Cell No. +92-344*******

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