Project Manager Quality

Ravi Kumar Mainali

Dallas, Texas

LinkedIn Link: www.linkedin.com/in/ravi-mainali-ms-energy-pmp-clssbb-iso-auditor

CAREER SUMMARY:

Energy Solutions Consultant, Renewable Energy Project Manager, Helping to Reduce Energy Cost & Achieving Sustainability

Energy & Resource Efficiency: Strong background in energy management, resource optimization, and sustainability, Flue Gas Monitoring & Control; Energy Auditing Certified.

Business Processes / People Management / Systems Engineering

Results-driven Mechanical Manufacturing & Energy Engineer with over 30 years of experience in precision engineering (machine shop & fabrications) and FMCG Companies

Certified with PMP, Lean Six Sigma Black Belt, ISO 9001 Auditing Certified

Experienced in heavy manufacturing, chemical processing, food & beverage industries with SAP ERP system

Results-driven leader with expertise in driving operational excellence, process improvements, and energy efficiency in FMCG and durable precision Products manufacturing environments

Continuous improvement, operations / Process Engineering, Shopfloor management, SAP System, energy efficiency and Sustainability program management

Professional Experience:

Energy Solutions Consultant and Renewable Energy Project Manager

Navigate Power & Verde Solutions, Dallas

Feb 2025- Present

• Developed and implemented energy solutions for companies, reducing overall energy costs by 15-25% with attractive ROIs.

• Conducted audits on energy consumption and demand side management to optimize peak demand charges. Energy Efficiency Audit of the facilities/operations.

• Collaborated with clients to design and install renewable energy and battery storage systems, energy procurement with locking the energy rates strategically in highly volatile and deregulated energy markets.

• Energy procurement with locking the lowest possible energy price strategically in highly volatile and deregulated energy markets.

• Energy Bills Auditing to verify over-charges and getting refunds from the energy suppliers.

• Comprehensive support & solutions on HVAC, Combine Heat & Power (CHP), LED Lighting Services

Business Process Improvement Manager (PMO Manager)

Hensley Industries (Division of Komatsu Ltd), Dallas, TX

March 2022 – Nov 2024

Spearheaded business transformation initiatives, aligning with corporate goals to improve operational efficiency, developed KPI for delivery performance compliance.

Led SAP process improvement projects (PP, MM, SD), reducing product lead time by 35% in 1 year.

Utilized Smartsheet for seamless process automation across the value chain, driving efficiency gains.

Weekly CFT meeting for Order Fulfillment Monitoring and Backorders analysis and developed SOPs.

Conducted Kaizen events and implemented DMAIC and PDCA for continuous improvement.

Developed and executed SOPs, policies, and frameworks to ensure long-term sustainability of process improvements in six months’ time. Order Management (Quote-to-Cash), Analysis of Data and Backorders

Training to all level of employees on OSHA ISO 45001:2018 and EMS ISO 14001 including corporate leaders

Led cross-functional teams to deliver projects on time and within budget while maintaining strong customer relationships. Expert in contract management, understanding contract law, codes, and standards, with the ability to analyze control system drawings and schematics. Expert in delegating tasks and empowering team members to achieve high performance and project goals.

SAP PM Master Data Consultant (Sr. Engineer)

Nestle, Anderson, Indiana (Contractor: FTE with LTTS)

Jan 2021 - Oct 2021

Configured plant maintenance master data, optimizing equipment hierarchies and enhancing asset management in 9 months project.

Led maintenance strategy implementations, improving OEE through effective planning and execution.

Conducted cost analysis and improved operational efficiency through streamlined maintenance processes.

(Career Break: Aug 2019 – Dec 2020: Moved to USA from Nepal; Joined Master’s Program at UNT, Denton, TX)

Chief Executive Officer

Spring Mineral Water (RO Processing and Bottling of Water), Nepal

Jun 2015 - July 2019

P & L Responsibility of the business. Drove process improvements resulted in a 20% revenue increase in.

Obtained ISO 22001:2005 certification, launching high-end bottled water products.

Managed P&L, overseeing 15 employees, and implemented effective leadership strategies.

Senior Technical Expert

ASSIST, Philippines, Remote from Nepal

Apr 2013 – May 2015

Promoted resource efficiency in Southeast Asia by optimizing energy, water, and material usage.

Trained national consultants and conducted over 40 audits for small & medium-sized industries.

Achieved a 15% increase in resource efficiency and minimized carbon footprint in three years project.

Assigned to Projects Sustainable & Efficient Industrial Development (SEID) & Sustainable Actions & Vision for Environment (SAVE)

Adjunct Instructor

Institute of Engineering, T.U., Thapathali, Nepal

Dec 2008 - Nov 2018

Taught engineering subjects, such as Manufacturing Technology, Energy Efficiency & Audit, Industrial Management, and TQM, at the Industrial Engineering undergrade level.

Principal Consultant

Aim Engineers Pvt. Ltd. (SHE and Productivity Consulting Firm), Nepal

Dec 2008 – Mar 2013

Industrial Consulting and SHE Training to Factory Inspectorates, Industrial Managers, boiler & utilities plant operators on behavior-based safety (BBS), Energy Efficiency and Auditing.

Insurance Loss Adjustments and Appraiser of Banks for Home & Equipment Loan lending process.

Plant Engineering and Maintenance Manager

Bottlers Nepal Ltd (The Coca-Cola Bottlers)

Jun 2007 - Nov 2008

Managed plant maintenance, increasing boiler efficiency by 6% through steam recovery and insulation improvements.

Implemented operational excellence initiatives, enhancing plant OEE and reliability.

Monitoring of Overall Utilities Equipment including Boiler & Chiller, and Air Compressors Performances (Flue Gas Temperature, Condensate Recovery Water Temperature Tracking, Air-Fuel Ratio Analysis).

Experienced Project Manager with 2+ years in the building automation and controls industry, specializing in HVAC control systems.

Proven track record in planning, scheduling, and coordinating resources to ensure project success from initiation to completion.

Adept in managing project financials, including billing revenue forecasts, change orders, and subcontract negotiations. I am skilled in preparing and reviewing project documentation such as RFIs, punch lists, meeting minutes, and submittals, ensuring compliance.

Project and Maintenance Engineer

Unilever Nepal Ltd, Nepal

Dec 2003 - Jun 2007

Led energy-saving projects, optimizing batch cycle time and increasing material yield.

Enhanced plant reliability through root cause analysis and effective maintenance strategies.

Monitoring of Overall Utilities Equipment including Boiler & Chiller, and Air Compressors Performances (Flue Gas Temperature, Condensate Recovery Water Temperature Tracking, Air-Fuel Ratio Analysis).

Operations, Monitoring and Control of Wastewater (Effluents) Treatment Plant discharged from Soap & Chemical, and Personal Care Products processing plant

Plant Engineer (Head of Engineering)

United Breweries (UB Group), Nepal

Apr 2002 - Dec 2003

Managed resource efficiency and production quality through effective planning and cross-functional. collaboration. Plant Engineering and Maintenance of Overall Plant.

Monitoring of Overall Utilities Equipment including Boiler & Chiller, and Air Compressors Performances (Flue Gas Temperature, Condensate Recovery Water Temperature Tracking, Air-Fuel Ratio Analysis).

Development of Safety Policy, Procedures (SOPs), and Work Instructions (WIs) and subsequently. training and empowerment of safe working practices as an integral part of the business process.

KPIs Tracking and monitoring safety performance of the shop floor and preparing monthly report.

Promotion of Proactive Safety Culture, Capturing Accident/Incident and Investigating the root causes and development of countermeasures to avoid recurrences of similar accident/incident.

Shift Manufacturing Engineer

Varun Beverage Nepal Pvt Ltd (Pepsi-Cola Bottlers), Nepal

Dec 2000 - Apr 2002

Shift Operations, Manufacturing & Maintenance of the Plant, Resources Yield and KPIs Tracking

Monitoring of Boiler & Chiller Performance (Flue Gas Analysis, Condensate Return Water Temp Tracking).

KPIs Tracking and monitoring safety performance of the shop floor and preparing monthly report.

Sales & Service Engineer

A. S. Overseas Trade Link (Burgmann India Pvt Ltd) Nepal Territory

Sep 1999 - Dec 2000

Market Promotions, Sales & Distributions of Burgmann Mechanical Seals and Gaskets Products.

Exposures of intensive training on mechanical seals manufacturing and servicing process for 6 weeks.

B2B Promotions of OEM (Burgmann) Products across the country in Nepal.

Visited over 200 process industries all over the Nepal to generate sales of Burgmann (OEM products).

Production Engineer (Machine Shop Floor Supervisor)

SIM Industries (Manufacturer of Jig & Fixture- Tool Room Works), Mumbai Oct 1995 - Aug 1999

Shift Operations, Manufacturing Process Control, Interpretation of Component & Parts Blueprints.

Development of working drawings and work order process management.

In-process and final quality inspection and control of dimensional precision control (tight tolerance of +/- 10 Microns) and other physical parameters.

KPIs Tracking and monitoring safety performance of the shop floor and preparing monthly report.

Apprenticeship & Shopfloor Trainee Engineer

Dagger Forst Tools Ltd (Manufacturer of Broaches & Cutting Tools), Mumbai

Mar 1994 - Oct 1995

Overall deeper level of exposures for Soft Machining such as Turning, Milling, Drilling, and Shaping, Heat Treatments, Grinding and Tool Room, Jig & Fixtures, and Component Design.

Quality Control, Precision Engineering, GD&T, Worked under the origination phase of ISO 9001:1987 Standard. Safety Audit and Training to shopfloor machine operators.

In-process and final quality inspection and control of dimensional precision control (tight tolerance of +/- 5 Microns) and other physical parameters.

KPIs Tracking and monitoring safety performance of the shop floor and preparing monthly report.

Education:

MS in Engineering Management - Energy, UNT, Denton (Dec 2024)

Master of Science in Engineering Management, Purbanchal University, Nepal (2017)

Thesis: Energy Management

AMIE in Mechanical Engineering, Institution of Engineers India (2004)

Focus: Manufacturing Technology, Material Handling, Machining Systems

Diploma in Mechanical Engineering, Institute of Engineering, Thapathali, Kathmandu (1993)

Certifications:

Project Management Professional (PMP), PMI (Sept. 2024)

MITx-Chief Operating Officer (COO), MIT (Expected Apr 2025)

Lean Six Sigma Black Belt, SSGI (2021)

Earned In-house Certification as an Amazon Robotic Technician

Certified Energy Manager (CEM) (Undergoing)

OSHA 30 HR Training (April 2025)

OSHA 10 HR and NFPA 70E (2020)

QMS ISO 9001:2008 Lead Auditor (IRCA, 2012)

Energy Auditor (BEE India Curriculums, 2012)

Training of Trainer for Master Trainer; M-ToT for Technical & Vocational (TITI Nepal, 2013)

SKILLS:

Project and Program Governance: Development of Governance Frameworks, Policies and Procedures

Vendor & Budget Management: Capital Projects budgeting, cost control, and managing vendor relationships to ensure timely delivery of equipment and services. Expertise in Project Commissioning - FAT/SAT & DQ/IQ/OQ/PQ.

Operational Excellence: Expertise in Total Productive Maintenance (TPM), Total Quality Management (TQM), Development and Tracking of KPIs, and driving process optimization; ISO 900:2008 Auditor Certified.

Maintenance & Reliability: Skilled in predictive and preventive maintenance, FMEA, FTA, 5 “Why” for RCA, OEE improvements, and reliability enhancement, Boiler & Utility, Predictive Maintenance

Energy & Resource Efficiency: Strong background in energy management, resource optimization, and sustainability, Flue Gas Monitoring & Control; Energy Auditing Certified.

SAP Expertise: SAP PP, MM, SD, and PM modules for process improvement and material requirements planning.

Team Leadership & Change Management: Proven leadership in driving organizational change and fostering high-performance teams.

Health, Safety & Environmental Compliance: Strong understanding of HSE standards and risk assessment & analysis PSA, JSA, HAZOP, LOTO; Certified in NFPA 70E and OSHA, Proven Behavior-Based Safety (BBS) Trainer.

Cross-functional Collaboration: Successful at working with diverse teams to align business strategic directions & goals and ensure project success and deliverables.

GD&T and Precision Engineering: Hands-on in Fabrications and Machine shops.

Quality Tools: TQM, TPM, Pareto Chart, SQC- Cp, Cpk, Pp, Ppk and Problem Solving

Advanced Excel: Data Analysis and visualizations via Excel V-Lookup, Pivot Tables, Power BI

Lean Six Sigma: Proficient in DMAIC, Kaizen, PDCA, and Value Stream Mapping (VSM) for continuous improvement; LSSBB Certified, Process Flow Diagram with Visio, SMED, and 8Ds.

Languages:

English (Fluent) II. Nepali (Native) III. Hindi (Fluent)

Work Authorization Status: US Citizen and currently holding valid US Passport

Contact this candidate