Senior Production & Plant Operations Engineer

SHAHID ASHRAF

Senior Production, Planning & Plant Operations Engineer

Heavy Fabrication Pressure Parts Structural Steel Boiler Manufacturing Oil & Gas GCC Experience

+91-703******* ************@*****.*** Mumbai, India Ready to relocate (GCC) Professional Summary

Accomplished Mechanical Engineering Professional with 17+ years of progressive experience in Production Management, Production Planning, Plant Operations, Heavy Fabrication, Structural Steel, Pressure Parts, and Boiler Manufacturing across India and Saudi Arabia. Proven expertise in leading end-to-end manufacturing operations, optimizing production processes, and delivering projects on time while ensuring the highest standards of Safety, Quality, Cost, and Delivery (SQCD). Demonstrated success in leading and motivating cross-functional teams of 150+ personnel, building high-performance work cultures, enhancing workforce productivity, and developing future leaders through effective coaching and team engagement. Strong expertise in Lean Manufacturing, Capacity Planning, Production Scheduling, Material & Resource Management, Continuous Improvement, and Root Cause Analysis. Proficient in Primavera P6, MS Project, SAP, ERP Systems, and Advanced MS Excel. Recognized for improving machine productivity by 20–30%, reducing RT repair rates from 5% to 1%, and increasing production capacity from 550 MT to 800 MT through process optimization and operational excellence.

Career Highlights

17+ years in Production, Planning & Plant Operations

Managed a workforce of 150+ personnel across manufacturing operations.

Improved machine productivity by 20–30%

Reduced RT repair rate from 5% to 1%

Increased monthly production from 550 MT to 800 MT without major capital investment.

Extensive experience in India and Saudi Arabia manufacturing environments.

Successfully optimized manpower utilization and production planning for higher operational efficiency.

Core Competencies

Production Management • Production Planning & Scheduling • Production Control • Plant & Shop Floor Operations • Manufacturing Operations • Heavy Fabrication • Boiler Manufacturing • Pressure Parts • Structural Steel • PEB Structures • Columns • Ducts & Hoppers • Water Wall Panels • Coils • Headers • Storage Tanks • Pressure Vessels • Welding Operations • Capacity Planning • Material Management • Resource Planning & Optimization • Cost Control • Productivity Improvement • Lean Manufacturing • OEE Improvement • TPM • Kaizen • 5S • Root Cause Analysis • Continuous Improvement • Team Leadership • Vendor Coordination • Primavera P6 • SAP • ERP Systems Project Coordination

Quality Management Cross-Functional Coordination• On-Time Delivery • Team Development • Plant Administration

Professional Experience

Production Manager / Plant In-charge

Thermax Ltd. (Vendor: Unitech Pvt. Ltd.) Feb 2021 – Present Roles & Responsibilities

Develop and execute production plans, schedules, and capacity planning to achieve monthly production targets.

Manage shop floor operations, manpower allocation, machine utilization, and resource planning to maximize operational efficiency.

Conduct daily production review meetings to monitor progress, resolve bottlenecks, and ensure timely project execution.

Coordinate with QA/QC, Procurement, Stores, Maintenance, Engineering, and Dispatch teams for seamless production flow.

Ensure timely availability of raw materials and production resources to eliminate manufacturing delays.

Supervise welding activities, WPS/PQR implementation, and fabrication processes in accordance with quality standards.

Optimize inventory utilization, material consumption, and production planning to minimize wastage and improve cost efficiency.

Prepare daily, weekly, and monthly production reports, progress updates, MIS reports, and management dashboards for senior leadership review.

Monitor production KPIs, productivity, and machine performance while implementing continuous improvement initiatives.

Drive Lean Manufacturing practices to reduce waste, improve workflow, and enhance overall plant productivity.

Lead, mentor, and develop cross-functional teams to achieve operational excellence and maintain a safe working environment.

Key Achievements

Increased machine productivity by 20–30% through process optimization and improved production planning

Reduced RT repair rate from 5% to 1%, significantly improving first-pass quality.

Improved production efficiency through better manpower deployment, machine utilization, and workflow optimization.

Successfully managed multiple manufacturing lines while consistently achieving production and delivery commitments.

Production Planning Engineer

International Building System Factory Co. Ltd., Saudi Arabia Sep 2017 – Dec 2020 Roles & Responsibilities

Planned and controlled production activities for PEB structures, structural steel, and heavy fabrication projects.

Prepared master production schedules and monitored manufacturing progress to meet delivery commitments.

Coordinated with Engineering, QA/QC, Procurement, Stores, and Dispatch for smooth production execution.

Managed material planning and ensured timely availability of production resources.

Optimized manpower utilization and machine loading to improve manufacturing efficiency.

Monitored production KPIs and implemented corrective actions to achieve operational targets.

Ensured compliance with international quality, safety, and fabrication standards. Key Achievements

Increased monthly production capacity from 550 MT to 800 MT without major capital investment.

Improved production planning accuracy, resulting in enhanced on-time project delivery.

Successfully managed production planning in a multinational manufacturing environment serving industrial and commercial projects. Senior Production & Planning In-charge

TBWES Aug 2013 – Jul 2017

Roles & Responsibilities

Managed production planning and manufacturing operations for boiler pressure parts and heavy fabrication projects.

Supervised shop floor activities involving Water Wall Panels, Coils, Headers, and Boiler Components.

Led a team of 20 supervisors and 220–350 workmen to achieve production targets.

Coordinated production schedules with Planning, QA/QC, and Engineering departments.

Ensured adherence to quality standards, welding procedures, and safety regulations.

Optimized manpower deployment and machine utilization to improve productivity.

Monitored production progress and resolved manufacturing bottlenecks. Key Achievements

Successfully executed multiple boiler manufacturing projects within planned schedules.

Improved coordination between production, planning, and quality functions. Plant In-charge / Production Manager

Thermax Ltd. Aug 2006 – Jul 2013

Roles & Responsibilities

Managed manufacturing operations for boiler components and heavy fabrication.

Supervised production planning, manpower management, and shop floor activities.

Coordinated with Quality, Maintenance, and Planning teams for smooth production flow.

Ensured compliance with safety and quality standards throughout manufacturing processes.

Monitored production performance and implemented process improvements.

Developed production schedules to achieve customer delivery requirements.

Trained and guided supervisors and workmen to improve operational performance. Key Achievements

Progressed through multiple leadership positions based on consistent performance.

Successfully managed boiler manufacturing operations while maintaining production efficiency.

Production Engineer

Shubham Udyog Pvt. Ltd. Jan 2006 – Jul 2006

Roles & Responsibilities

Assisted in daily production planning and shop floor operations.

Supervised fabrication activities and monitored production quality.

Coordinated with production teams to achieve daily manufacturing targets.

Ensured compliance with safety procedures and quality requirements. Production Engineer

Unimech Industry Sep 2004 – Dec 2005

Roles & Responsibilities

Supported production activities for fabrication and manufacturing operations.

Assisted in production scheduling, material coordination, and quality inspections.

Monitored machine utilization and ensured adherence to production plans.

Maintained production records and coordinated with cross-functional teams for timely execution.

Education & Certifications

B.Tech in Mechanical Engineering

Diploma in Mechanical Engineering

Saudi Council of Engineers (SCE) Certified

Degree attested by Indian & Saudi Embassies

Software Skills

Primavera P6 MS Project SAP ERP (Baan) MS Excel MS Word PowerPoint

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