Continuous Improvement Heat Treat

resume

RANDHAM SUBRAMANI RAVI

Professional Engineer of Ontario

License NUMBER 100219052

ADDRESS ***, ****** ********, ******

Ontario, Canada K1T0S5

CONTACT +1-256-***-****

***********@*****.***

Preferred Mode of communication – Email

Educational Qualification - bachelor’s degree in engineering (Mechanical)

Post Graduate Diploma in Steel Plant metallurgy

Licensed Professional Engineer of Ontario, Canada

Country of residence - Canada, Citizen of Canada

Summary of Experience

Experience in Operation, process optimization,maintenance, finishing, shipping and downstream processing of hot rolled coils produced through Conventional 1+6 stand continuous hot strip mill from 210 mm thick slabs, 7 stand CSP from 50 to 70 mm thin slabs, 1+6 stand DSPC from 100 mm thin slabs, Plates produced in Plate mills of steel plant including Plate finishing facilities like Plate heat treat furnaces, heavy plate levelers, cut to length line for hot rolled coils, operation of pickling lines for hot rolled coils.

Technology and continuous improvement projects and activity in Hot strip mills and CSP.

Worked as head of projects and operations for the 3 million tons per annum CSP project with SMS Germany for production of hot rolled coils for tata steel at Jamshedpur plant.

Worked as head of operations for 4 million tons per annum hot strip mill for Bhushan steel in Angul location in India. All above Hot strip mill projects were done with technology and main equipment supplied by SMS, Germany.

Worked as Director operations and projects for 1 million tons per annum Plate mill and 1 million tons per annum stainless steel plant green field project of Jindal steel in the state of Orissa in India at a capital cost of 2.5 billion USD. This project had 3 million tons per annum steel making shop from SMS, 3 million tons per annum hot strip mill from Siemens, 3 ferro alloys furnaces, 1 coke ovens plant and a cold rolling mill from Andritz along with associated supporting facilities for all utilities like water, gas, oxygen, scrap processing, electrical power systems, rail road construction to complete the project along with a 2X250MW thermal coal fired power plant.

Worked as General manager for the 166-inch Plate Mill, 106-inch mill Hot strip mill, 80-inch cold rolling mill, heat treat facility for plates and various strip processing units like cut to length unit, tempering and skin pass mill for Essar Steel Algoma Inc in Sault Ste. Marie, Ontario, Canada.

Completed number of continuous improvement projects like TPM (total productive maintenance), TOP (total operating performance), EVA (economic value addition-based projects) in hot strip mill of tata steel.

Managed all safety functions as required for zero accident and zero injury in plant and projects in a unionized 24/7 operation environment.

One of the key decision makers in procurement function for the work rolls, back up rolls various table rolls, stripper nose, roll bite cooling headers, descaling headers and nozzles, roll cooling nozzles and headers and roll bite lubrication oil and pinch rolls for down coilers of HSM maintenance spare parts, services and CAPEX items of the company with experience in operational and project purchases through knowledge of vendors in Canada, Europe, USA, China, India and Germany.

Certificate of Honor as a team member for winning national award for Tata Steel for developing high strength dent resistant formable steel for Auto exterior panel applications.

Key Achievements in Hot strip Mill / Plate Mill

Established the 3 million ton per annum CSP from scratch – technological lay out selection, process stabilisations, training of operators, best utility systems for water, air, hydraulics, shipping logistics for achieving ship on time for customers, product development, cost reduction and scrap disposal

Eliminated the roll edge spalling and roll failures in Plate mill with improvement in schedule size.

Developed 3-inch plate for A36 grades with available 8 inches thick slab and low powered plate mill.

Improved overall yield of plates rolled through 166-inch mill and finished through shearing and flame cutting line by 0.50%.

Developed laser cutting grade plates through 166-inch Plate mill and CTL line for plate coils produced through 106-inch mill.

Implemented Hydraulic screw down and controls for 166 Inch Plate Mill.

Reduction in rejection because of edge cut in cross rolled plates.

Reduction in roll breakages in Quench, tempered and normalizing heat treat furnace for the Plates.

completed many automation projects in Plate mill to reduce the manpower.

Reduction in scale loss by 0.25 % with improved surface quality.

Developed Tank car grade plates for Rail tank car manufacturer in USA.

Development of Mill edge plates to the satisfaction of end customers.

Improved ship on time for all plate products to 90% from the historical levels of 52%.

Increased the furnace campaign life from average of six months to more than a year through improved heating practices, implementation of right quality of skid riders which also reduced the skid marks on plates, use of precast refractories for roof and skid pipe insulation.

I identified and stopped loss making business of unshorn plates through 166-inch plate mill of Algoma Steel with a customer named SIS whereby party used to get 17% free of cost and used to sell back the scrap to Steel Company.

Developed and stabilized the thermos-mechanical rolled wind tower grades for CS wind, Windsor and Marmen, Quebec saving huge cost to company, a good product to customer and since 2011 to 2015 every year we rolled out almost 120,000 tons per Annum.

Initiated 100% bottom surface inspection of all surfaces critical plates and established the product and product route for trinity rail car tank material with very low rejection at customer’s end.

Completely eliminated the Back- up roll spalling issue from 166 inch,106-inch mill HSM, 2150mm hot strip mill of Stelco and AMNS.

Work Roll failures in 166inch mill and 106-inch mill brought down to zero with improved practices and technical modifications.

Brought down the roll cost by 25% through proper selection of roll material and techno – commercial condition of purchase with roll vendors.

Reduced the unwanted thicker gauge production during start up to just one coil for the 106-inch hot strip mill of Algoma.

Increased the coil weight for 96-inches width coils to 12 tons from earlier value of 10 tons.

Have worked in a roll shop since the project inception and worked as head of operation and maintenance of roll shop catering to a 3 million tons hot strip mill.it had two grinding machines for work rolls for finishing mill, 1 grinding machine for RM work roll and 1 grinding machine for back up roll and I lathe machine for removing cracks and minor spalls.

Managed all the performance data for all the work rolls, back up rolls, edger roll and pinch roll with respect to tons per mm, wear rate, failure rates vendor wise and all other relevant reason wise for analysis and improvement of roll life.

Reduced the roll cost of HSM through analysis of failures and almost eliminated the most failures like spalling of back up rolls, roll breakage and banding defect.

Implemented various technology along with mill operation to improve roll life and increased the schedule length.

Established the process of regular monitoring of exit roll condition and using the data for improvement in roll life and mill up time.

Have experience in implementing HSS rolls in early stands of finishing mill and very effective CPC rolls with huge improvement in schedule length and surface quality of strip.

Implemented and have knowledge of the right quality of back up rolls stand wise, vendor wise and quality wise like forged back up rolls, cast back up rolls.

Have made a system of monitoring the performance of grinding wheel consumption in roll shop.

Achieved the target of no delay on account of roll shortage in HSM ready rack for rolling through implementation of proper systems and procedures.

Improved the availability of grinding machines through preventive maintenance procedure and implemented TPM in roll shop.

Worked in 106-inch hot strip mill of Algoma steel Inc. Located at Sault Ste. Marie, Ontario, Canada - an integrated steel plant of 3 million tons per annum capacity till 28th February 2018 and reduced the roll failure to zero in last 4 years. Implemented suitable qualities of rolls for each stand and stabilized the system of roll movement stand wise for optimum inventory of rolls in roll shop.

Reduced the roll purchase cost by bringing in good quality roll suppliers with right price of rolls for HSS, High chrome, ICDP and 5% and 3% Cr Forged back up rolls.

Provided consultancy for Roll shop of 4 million tons per annum hot strip mill for Bhushan steel in Angul location in India. All above Hot strip mill roll shop projects were done with technology and main equipment supplied by Waldrich, Germany.

Completed number of continuous improvement projects like TPM (total productive maintenance), TOP (total operating performance), EVA (economic value addition-based projects) in roll shop of hot strip mill of tata steel.

Managed all safety functions as required for zero accident and zero injury in plant and projects in a unionized 24/7 operation environment.

Implemented roll bite cooling and roll bite lubrication in early four stands of hot strip mill.

Improved the entire high-pressure descaling system in front of Finishing mill for better descaling, reliable quality and no interruption due to failure of descaling in hot strip mill.

Implemented CVC technology in all six stands of finishing mill of hot strip mill along with SMS the technology supplier of CVC which included a grinding machine from Waldrich Siegen, Germany.

Eliminated the roll edge spalling and roll failures in Plate mill with improvement in schedule size.

Reduction in roll breakages in Quench, tempered and normalizing heat treat furnace for the Plates.

Developed wind tower grades through 166 Inch Plate mill through thermo- mechanical rolling route avoiding the expensive heat treatment process saving almost 50$ /ton saving for the company.

Developed various grades through CSP like HSLA up to 100 KSI strength, HR for CR, HR for HRPO, API X -70, CRNO, LC EDD.

History of Employment

POSITION

COMPANY

DURATION

RESPONSIBILITY

Area Manager process improvement and technology Hot strip mill

Stelco, Canada

From Nov 2022

Process improvements in all aspects of Hot strip mill operations, drive upgrades to AC drives, recuperators Improvements, RHF combustion improvements, reduction in Roll Cost in HSM, Improvements in roll shop practices in HSM and cold mill.

Area Manager Continuous Improvements and technology Hot strip mill

Arcelor Mittal Nippon Steel, Calvert, Alabama, USA

From May 2018 to September 2022

Responsible for continuous process improvements in a 5.5-million-ton Hot strip mill.

General Manager Flat rolled Division (106 inch 1+6 stand continuous Hot strip mill, DSPC 166-inch Plate Mill, 80 Inch Cold rolling mills complex, Plate shearing and cutting line, Heat treat lines for plate products, skin pass mill for coils, CTL) at Algoma Steel, Canada

ALGOMA STEEL

CANADA

22nd Nov 2010 to 28th Feb 2018

Responsible for entire operation, Maintenance, customer order compliance, customer complaints and ship on time of products through these producing units at Algoma Steel, Canada.

Director (Projects and Operation), Jindal Stainless Steel Ltd, Orissa, India

JINDAL STAINLESS STEEL

August 2008 to Aug 2010

Responsible for overall project execution of the 1 million ton per annum integrated stainless steel plant comprising 3 ferro-alloy furnaces, steel making shop, hot strip mill and 2x250 MW coal fired thermal power plant

Chief of CSP project and head of operation

TATA STEEL

July 2004 to July 2008

Completion of engineering project and stabilization of 3 million tons per annum compact strip production. Various technological improvements in thin caster for improvements in productivity and reliability and new product development.

Divisional Manager Operations, HSM, Tata Steel

TATA STEEL

June 1988 to July 2004

Worked as project head with overall responsibility of putting up the 2 million tons per annum HSM & increasing the capacity of hot strip mill to 4.0 MTPA at capital cost of 1 billion USD and 900 million USD for expansion.

Process Engineer hot strip mill

TATA STEEL

July 1982 to May 1988

Responsible for making all SOPs, product development, process parameter analysis and stabilization, yield and rejection analysis and reduction.

Summary of key expertise

Commissioning, stabilizing the processes, training to operators, making blue print for operational performance reporting

Operational performance improvement and core business management

I have worked on improving the operational performance and study of core business process to reduce cost and improve the yield for Tata Steel along with McKinsey Consultant under the Total operating performance (TOP) and brought in a saving of more than 10 million INR for only the Hot rolled division. Later on, worked independently for the entire flat rolling Division including supply chain, marketing and sales division to rake in 50 million INR. I was trained by McKinsey consultant on their EVA and EBIDTA based system for improvement of operating performance.

Operational Cost reduction and Process redesign for customer focus

I have worked on operational cost reduction through various initiatives yield improvement, wastage reduction, process improvements, manpower optimization, product mix optimization, process reengineering, reduction in rework and cost of poor quality, making improvements in earnings through supply chain rather than making profits through transactions. Understanding process of customer’s customer and making the entire value chain efficient and profitable. Through study of cost sheet and expenses to understand wasteful expenses and taken initiatives to reduce and eliminate them. Reduced the cost of HR coil produced in tata steel from almost 550 USD per ton to 425 USD per ton. The yield of hot strip mill was improved from 96% to 98.20% leading to exceptional saving of cost and free additional gross production. Entire Mill providing software was redesigned to take into account to meet customer delivery on time and in full.

Quality Improvements and Customer focus

I have worked in various quality improvement projects during my long career where by many products and quality improved for various customers like wheel and Rim, saw blade manufacturers, service centers in USA and Canada, Improvements in Ship on time and quantities delivered in full with all varieties. Customers in USA who were benefitted are McNellis, Ryerson, Olympic and many plate and coil buyers.

Improvements in OEE

Provided leadership to companywide initiative in improving OEE across the plant through implementation of TPM, Kaizen, 5S. I was trained by Watanabe sun of japan and through in plant training in Nippon Steel Plant in Kimitsu, Japan. I have implemented autonomous maintenance and predictive maintenance in strategic units of production in tata Steel, Jamshedpur Plant. The plant availability, rejection rate and productivity improved leading to improvements in OEE.

Change management

Provided leadership to cultural changes through ASPIRE movement in Tata Steel to improve the EVA, EBIDTA, Customer focus, cost reduction, Ship on time in full and continuous improvements. Many improvements, starting from grass root level to business decision process were brought about. Actively Digitization one of the key requirements for any industry today has resulted in simpler process with customer in the center of all objectives. Digitization included a customer order status display to dispatch tracking to employee salary to simple travel bill payment for the employees.

Procurement and Supplier collaboration in strategic areas for reliability and quality improvement

I have implemented and practiced Strategic Purchasing procedures and systems for key raw materials and operational consumable which directly affect the operation and quality of end product like rolling oil, work rolls, back up rolls, furnace riders, ferro Alloys, graphite electrodes, emulsions, lubricating oil and grease, critical spares from life cycle costing point of view and resultant cost of poor quality where ever applicable. The procurement was just not limited to local but in most area global procurement action was initiated. For strategic items the items were purchased from japan at a higher price too, long term contracts were finalized for items like industrial gases, ferro alloys, product packaging, inbound and outbound logistics and many other items. We started many service centers to meet in just in time requirement for customers where company maintains the ready stock depending upon customers consumption pattern and forecast.

Project Management & Capital expenditure

I have worked on many capital projects green field and brownfield in India, Canada and in many locations. The responsibility included project conceptualization, proof of the need, feasibility studies, projected EBIDTA and cashflows for post project implementation, selection of technology vendor selection for key services and equipment procurement, consultants and contractor selection, organizing resources, project planning, project management, monitoring project execution and commissioning within time and budget, post audit of results of capital expenditure. Following are examples of some of key accomplishment –

4 million tons hot strip mill project for tata steel in India in Jamshedpur location at a capital cost of 1billion USD in 3 stages.

3 million tons CSP in Jamshedpur, India location for tata steel at a capex of 1.1 billion USD

1 million tons per annum stainless steel project for Jindal stainless steel

REFERENCES

Mark Nogalo - Vice President (Operations)

105, West Street, Algoma Steel Inc, Sault Ste. Marie Ontario, Canada, P6A7B4

E Mail – ****.******@******.***

Phone +1-705-***-****

Binu Abraham- Project Manager, Arcelor Mittal Nippon Steel, Calvert, Alabama, Phone -251-***-****, E Mail -****.*******@*************.***

Sameer Sharma – CEO, AJ Steel Pipes and Tubes, Abhu Dhabi

Phone number - +975********, E Mail – ****************@*****.***

RANDHAM SUBRAMANI RAVI

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