Time Delivery Plant Manager

SUMAN MANDAL

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~ Visionary Metallurgical Engineer ~

Quality Process Enhancements Product Development Customer Service Production Planning Procurement System Audit Greenfield Project SAP & Oracle AN OVERVIEW

Accomplished career growth with over 28+ years of experience in Quality, Process Enhancement, Product Development, Customer Service, Continuous Improvement, Metallurgical Lab operation (Defect Characterization), Metallurgical Operation, Consumable & Spares Procurement, System Audit, and SAP/MII Implementation.

Skilled in Quality, Process, Product, Manufacturing and achieving the desired targets.

Deft in managing diverse range of metallurgical activities such as evaluation of material characteristics, production, Process control & Quality assurance.

Demonstrated analytical, problem solving and organisational ability coupled with strong communication and relationship management.

Proficiency in Aluminium Casting – Continuous Casting & Direct Chill Casting, T-Bar, EMC Slab Casting, Ingot Casting (Alloy & Non-alloyed), Billet Casting, Remelt Furnace, Cold Rolling (Sheet), Hazlet Twin Belt Caster, Hot Rolling and Finishing line operation, Start-up and commissioning (Greenfield and Brownfield) of CC & EMC Slab Casting Plant, Pechiney Technology Transfer for Light Gauge Rolling; Customer Complaint Handling, Process Route & Product BOM, New Product Development, Spectrometer Operation, Metallography Analysis, Physical & Mechanical Testing, Limca, Alscan and Podfa analysis, Defect Characterisation (EDX and SEM), Casthouse Procurement (Ingot and Slab Area), Training & Development, Graphite Electrode (Extrusion, Baking & Graphitization) Manufacturing Technology.

Areas of Excellence:

EMC Slab Casting (Can & Automotive)

Planning, Process Route, BOM

Production & Quality Management (IMS)

Greenfield Project (1st Hot Metal)

Continuous Improvement

Operations (Casting & Rolling)

Aluminium Recycling & Dross conversion

Start-up & Commissioning

Qualification process of Products

Metallurgical Analysis (SEM and EDX)

SOP and Process Enhancement

T Bar, Ingot (Alloy) and Billet Casting

Handling Customer Complaint

Auditing – NABL, IMS, ISMS, BCMS

TS 16949 Audit (Automotive Stock)

Oracle-11i/SAP Implementation

QC check on Incoming material

TS 16949 Audit (Automotive Stock)

APQP, PPAP, FMEA,8D,5W, SPC, RCA, TQM

Development of New Products (Rolled)

Technical Training

Limca, Podfa and Alscan analysis

SPECIAL MENTIONS

Commissioning & stabilizing T Bar, EMC Slab, Ingot Casting, Continuous Casting

Stabilizing Melting cum Holding Furnaces as a member of Start-up & Commissioning Team.

Successfully stabilised light gauge foil rolling (6.35 microns) through Concast route with global benchmark target

(Core member of Pechiney Technology Transfer Team for Light gauge Rolling)

Commissioning & stabilizing Tension Leveller line

Significant contributions in:

Improving power productivity as well as stabilizing preheating practice of Rolling Slabs by coal gas for Hot Mill rolling.

Stabilising hard alloy Casting & Rolling - 3XX & 5XX series.

Development of Annealing Practice for downstream Rolled Products

Handling Customer Complaints, conduct product Trials at Customer end

Reduce sales return

Enhancing customer satisfaction rating (CSI)

Process Control and Continuous Improvement in Aluminium Casting, Rolling and Finishing Lines

Assist in improving Delivery performance

Reducing pass schedule of downstream Products

Reduction in non-moving inventory & liquidation of aging stocks

Handled procurement of cast house consumables and implementation of KANBAN system

Improve overall Recovery

Aluminium Recycling, Dross management, Dross Metal Recovery.

Control on metal purity (PoDFA/LIMCA/ALSCAN)

Carried out NABL accreditation of Laboratory.

Development of New Products (e.g. Auto Fin stock, low Earing closure, thin gauge circle & lamp cap stocks etc.)

Led implementation of QS, EMS & OHSAS, Six Sigma and IMS (Integrated Management System), BCMS. ORGANISATIONAL SCAN

Jul’18 – till Date: Oman Aluminium Rolling Company LLC, Oman, Sohar as Process Engineer- Remelt

(Reporting to Plant Manager)

Jan’17 – Jun’18: Ma’aden Aluminium Company (Joint venture with ALCOA), Kingdom of Saudi Arabia, Ras Al Khair as Technical Superintendent, cast house (Reporting to Casthouse Director) Jun’15 – Dec’17: Oman Aluminium Rolling Company LLC, Oman, Sohar as Process Engineer, Remelt (Reporting to Technical Manager)

Dec’11-May’15: Ma’aden Aluminium Company (Joint venture with ALCOA), Kingdom of Saudi Arabia, Ras Al Khair as Supervisor, EMC Slab & Remelt (Reporting to Slab Manager) Sep’10 –Nov’11: Manaksia Ltd., Haldia, India as Plant Head, Aluminium Division- (Reporting to Director, Operations)

Mar’07-Aug’10: Graphite India Ltd., Durgapur as Senior Manager, Technical

(Graphite Electrode Division)

Apr’00-Feb’07: Hindalco Industries Ltd., Belur, Hirakud as Manager, Quality (Aluminium Sheet Division) Nov’93-Apr’00: India Foils Limited, Hooghly as Assistant Manager, Production & Quality

(Aluminium Sheet & Foil Division)

Commenced career with Macheff Machinery Pvt. Ltd., Kolkata as Graduate Engineer Trainee from Oct’92-Nov’93

(Wire Enamelling & Drawing Plant)

KEY RESULT AREAS

Strategic Planning

Designing strategies for the achievement of organisational vision and strategic direction.

Supervising production of various materials in fabrication & cast house in coordination with other divisions. Production

Supervising production related tasks including planning, control & troubleshooting for achieving the planned periodic schedules and process control.

Preparing operational budgets and ensuring adherence to the same.

Developing new process concepts for production optimization, yield improvement and developing guidelines for the sequencing of manufacturing activities.

Leading a team and attaining the monthly production targets as per the set targets and tracking progress against targets by analyzing daily reports).

Coordinating with the other departments for smooth functioning and accomplishing production as per customers’ requirement & organizational guidelines.

Minimizing performance bottlenecks for high productivity with maximization of men, material, cost and machine, etc; decreasing performance bottlenecks for high productivity by maximizing men, material & machine.

Monitoring the production status, procedures and systems followed in production to ensure compliance norms with desired quality and timely delivery of orders. Process Enhancements/ Continuous Improvement

Identifying scope for:

Planning / implementing technological changes to enhance efficiency.

Modifications in equipment, process flow, working practices, consumables etc. for controlling & reducing conversion cost per unit produced.

Calibration of instruments.

Pollution related activities.

Implementing various techniques for cycle time / cost reduction, entailing identification of opportunities, analysis of data, conducting tests, cost benefit analysis and implementation.

Conducting internal audits and highlighting any non-conformances / improvement areas.

Appraising the prevalent production systems/ processes, identifying loopholes if any and undertaking result- oriented measures for alleviating them and documenting the same.

Green Belt Projects on various Continuous Improvement in the field of enhancement of Productivity, reduction in Internal rejection, Reduce TAT, New Product development, Process reliability in Furnace & Casting areas etc. Quality Management Systems

Ensuring adherence to the quality standards such as WCM, TPM, SQC, 5S & Kaizen and overseeing implementation of various stages of workflow using quality tools.

Undertaking root cause analysis of problems and developing effective counter measures initiating Kaizen/ improvement ideas generation & implementation.

Carry out Internal Quality Audits, Implement Audit recommendation, Liaison with External Audit agency.

Facilitating Accreditation in ISO9001:2015, ISO14001, OHSAS18001, NABL (Laboratory), IMS (Integrated Management System), BCMS.

Taking stringent quality measures including preparation of necessary documents to ensure compliance with above standards & customer requirements.

Developing QAP & other quality certificates.

Operations & Maintenance

Planning and effecting predictive & preventive maintenance schedules for various equipment / lines to increase machine up time & equipment reliability.

Implementing maintenance schedules and carrying out periodic checks to ensure performance of various equipment and maintaining requisite documents for the same.

Proactively identifying areas of obstruction / breakdowns and take steps to rectify the equipment through application of troubleshooting tools.

Installation & Commissioning

Installation and commissioning of the heavy equipment as well as conducting tests & inspections to ensure operational effectiveness of plant & utilities.

Reviewing engineering drawings, layouts, diagrams, technical specifications, cost estimates for erection & commission of the plant; carrying out overhauling work of equipment, modifications, and major repairs to improve equipment efficiency by faultfinding.

Involved in installation, performance trials, system layouts and checks of main and auxiliary machinery and preparing documents for the same.

Dross Press Machine Installation, Dross- Metal recovery from Aluminium Melting.

Optimizing melting of Aluminium recycled scrap within benchmarking melt loss. SAP/ Oracle 11i Implementation

Understanding Business processes, study and analyse workflow to design solutions (As-Is and To-Be Analysis and Freezing).

Creating the business environment and prepare functional specifications.

Conducting gap analysis, assess scope of studies & suggested solutions through ERP.

Creating scheduling views, MRP views for materials, knowledge of MRP procedures, material types, etc.

Handling preparation of Masters like Material Master, Bill of Material, Resource/Work Centre, etc.

Managing testing, integration with other modules, integration testing & extending Post Go-live support. Procurement & Contracts

Successfully handled Cast house consumables and Spares for Ingot, Slab, T Bar and Billet areas.

Developed procurement process and contract (RTPC, price negotiation, Technical bids) with various suppliers.

Finalization of specification for consumables, standardization of minimum operating level.

Implementation of KANBAN system in Cast house stores. Client Relationship Management

Ensuring speedy resolution of queries & grievances to maximise client satisfaction levels.

Enhancing customer satisfaction matrices through on-time delivery of products as well as monitoring the customer complaints.

Assessing the customer feedback, evaluating areas of improvements & providing critical feedback on improvements.

Team Management

Leading, mentoring & monitoring the performance of the team members to ensure efficiency in process operations and meeting of individual & group targets.

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

SIGNIFICANT HIGHLIGHTS

At Oman Aluminium Rolling Company LLC:

Provided Technical support for start-up and commissioning of Antimony Processing unit (Furnace & Casting Line)

New Alloy Casting (1350/3003/8011/5010/5052/5182/7072) through Hazellet Twin Belt Caster

Reduction in scrap Inventory

Improve Efficiency of Remelt Furnaces and reduce Furnace TAT

Installation of Level-2 scada system in in Remelt/ Caster

Implementation of IMS (Integrated Management System in Remelt/ Casthouse)

Technical support to maintain right metal quality by ensuring Furnace operation practices

Imparted Technical Training to local crews (Omani) and access competency

Handling of testing equipment- Alscan and Podfa

Aluminium Recycling, Improvement on Dross-Metal Recovery

Reduction in melt Loss.

Engaged in commissioning of 120MT Melting cum Holding Furnaces

Alscan and Podfa analysis

Implementation of ISMS and BCMS.

At Ma’aden Aluminium Company:

Overall In-charge of Cast house Technical Department (Metallography Lab, Spectrometer, Process Control, Customer Service, System Audit)

Quality Improvement, Productivity enhancement and monitoring delivery performance

Key objective is to continual Improvement of Product, Process, on time delivery, customer complaint <0.5% of Shipment, decision on hold material (diversion/ rework)

Provide Technical support to customers

Finalize Technical contract for supply of Rolling Slab to Rolling mill and supply of liquid metal from pot room to casthouse

Visit Potroom to access right metal quality, monitor TAC quality of potroom metal

Finalizing Product Specification, Process Route, BOM etc.

Review and Finalize entire SWI of Casthouse area

Metallography Lab and Spectrometer operation (Defect characterization, Limca, Alscan and Podfa analysis)

Liaison with Internal (Potroom/Smelter) and External customer, coordinate for CSI rating, CAPAC on action items

Coordinate scheduled conference call with Sales, Customers and ATC (Alcoa Technical center)

Six Sigma Project to Improve Productivity, Cast Aborts, Internal Rejection in Slab, T Bar, Ingot and Billet areas.

Certification of ISO/TS 16949 for Automotive Alloy Casting

Stabilize Automotive Alloy (5xxx, 6xxx) Casting for Rolling Mill

System Management and implementation of Standard Practices in Canrec Furnace areas.

Implemented Scrap Management System

Training & Development to Local Saudi guys.

Implementation of Standard Practices in Carnes Furnace (Aluminium can melting) areas

Support higher management to achieve Casthouse objective and goal At Oman Aluminium Rolling Company LLC:

Quality Improvement and Productivity enhancement in Remelt

Scrap Management and effective handling system.

Imparting Training and develop Technical competency to new joiners/ locals

Developed Remelt practices for alloys 8011/1100/1070/1050/5010

Establish SWI’s and standard operating practices for Remelt

Six Sigma Project on API (Alloy Powder Injection) reliability

Enhance adherence of Internal Composition Limit

At Ma’aden Aluminium Company:

Hands on experience on Greenfield Project (1st Hot metal)

Successfully Commissioning & Start-up of T-bar (P1020), EMC Slab Casting (AA3104, 5182, 6014, 5754) and Ingot Casting Machines.

Process control of Slab & T Bar area from Furnace control, degassing, casting and sawing operation.

Imparting Technical & Safety Training to New Operatives in Cast house

Successfully handled Procurement of entire Casthouse department consumables, implementation of KANBAN system in stores.

Standardize metal quality and Installation of QC check Instruments, Limca, Alscan and Podfa, Analysis of defective Samples (EDX and SEM)

Liaison with Rolling Mill for Rolling Slab Supply contract, monitoring performance of Rolled Slabs (Hot & Cold Mill)

Process Routing and Item creation (BOM) of casthouse and rolling products.

Commissioning of Process Control Instruments viz. PoDFA, LIMCA and Alscan

Writing and documentation of Standard Work instructions, Procedure, Safe Practices (Best Practices-Alcoa system) Checklists etc. for Ingot, Slab, T Bar, Billet and Remelt area

Engaged in Start-up and commissioning of automotive stocks

Conducting Various CI Projects

Developed process check reports, PI (Performance Indicator) system for advanced process control

Liaison with Metallurgical Laboratory to ensure control on grain-size and inclusion level in cast products.

Documentation on LOTO (Lock out-Tag out) procedure At Manaksia Ltd.:

Increase in overall Production

Reduction in Conversion cost

Successfully commissioned Alloy Ingot casting line

Commissioned dross press to recover metal

Reduced melt loss in casthouse

Cost Calculation for entire plant (Operating and R&M)

Set Plant KPI and Targets and monitor its performance in daily basis

Development of New Products

Reduction in Customer Complaint

Improvement in Surface Quality of Rolled stocks

Implementation of PP module

Stabilising China continuous Casting machine and China Tension Levelling Line

Reduction in overall downtime

Meet with Shareholders

Participate in Customer meet, conferences

Improved on time delivery (In coordination with Sales & Logistic Team) At Graphite India Ltd.:

Played a key role in implementation of SAP & PP module

Pivotal in attaining zero overtime by multiskilling of operators.

Reduced customer complaint and development of cost-competitive Graphite Products.

Oversaw implementation of WCM concept in extrusion and finishing areas.

Efficiently carried out liquidation of salvage inventory

Introduced Department of the Quarter (DOQ) competition amongst all production sections. At Hindalco Industries Ltd.:

Instrumental in achieving Foil recovery as per benchmark figures with recovery and BPT (Breaks/Ton).

Generation of Process Route for Sheet Rolling Mill.

Essayed a crucial role in reusing ETP discharge & RO rejects.

Improved overall recovery in finishing lines (Slitters, cut-to length, bad saw, shearing and Tension levelling lines)

Acquired cost savings by using waste gas recycling for preheating purposes.

Initiated the process of tracking performance parameters through central Technical database (CTDB) starting from casting to shipment.

Metallurgical Structure of Aluminium Alloys, analysis of defects in Rolled Products (Hot & Cold Mill)

Stabilised tension leveller for degreased closure stocks.

Established autonomous maintenance in Cast house, Slitting line and WTP.

Stabilized Tension leveller for degreasing closure and lithographic stocks

Introduced delivery window in oracle system for instant overview of production status against valid order.

Got promoted as Manager from Assistant Manager in the year 2003.

Metallography Analysis of defective Samples, Alscan and Podfa analysis. At India Foils Limited:

Deftly handled successful transfer of Pechiney Technology.

Merit of:

Reducing sales return

Improving delivery performance

Decreasing Rolling Mill TAT (Turnaround Time) by modifying pass schedule in cast coils.

Enhancing export market by 5%.

Implementing Six Sigma in Gauge Control System.

Introduced concept of manufacturing group in cast house.

Setup the process of Internal Customer Satisfaction Index (CSI).

Was promoted to Assistant Manager from GET in the year 1995. At Macheff Machinery Pvt Ltd:

Day to day supervision of production process of aluminium wire drawing plant. PROFESSIONAL TRAININGS

Lead Auditor - ISO 9000:2000,

Internal Auditor – ISO 9000:2015, ISO 14001, OHSAS 18001, NABL, ISO/TS 16949, ISMS and BCMS

Performance Management

Finance for Non-Finance

WCM (World Class Manufacturing)

Lean Manufacturing

Balance score card

Analytical & Listening skill

Team Building

Negotiation skill

Green Belt – Six Sigma

SCHOLASTICS

1992 Bachelors in Engineering (4 year course) – Metallurgy from Bengal Engineering College, Shibpur. Secured 72%

1987 Higher Secondary Certificate (10+2 level) from Hare School, Kolkata, WBCHSE. Secured 60% 1985 Senior Secondary Certificate (10 Level) from Hare School, Kolkata, WBSEB. Secured 75% Academic Achievements:

Attained “8th Department Ranking” during B.E.

Obtained “National Scholarship” during Secondary Level PERSONAL DOSSIER

Date of Birth : 12th May 1969

Marital Status : Married

Family Details : Spouse (Housewife), Son (Studying in 12th Standard) Linguistic Abilities : English (Advanced)

GCC Driving License : Yes (Saudi/ Oman)

Office Address : Oman Aluminium Rolling Company

P.O Box-555, PC 322

Sohar Industrial Estate, Sultanate of Oman

Residential Address : Sohar, Al-Hamber, Oman

SUMAN MANDAL

01 February 2023

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