Mechanical Engineering Leader for Manufacturing Impact

CURRICULUM VITAE

NAME : Rakesh Kumar

FATHERS NAME : R. S. Tiwari

DATE OF BIRTH : 8th Sept. 1978

PERMANENT ADDRESS : Ahmedabad, Gujarat.

E- MAIL : ************@*****.***

CONTACT : +91-748*******

EDUCATIONAL QUALIFICATION:

1 -Completed 10th from Holy Cross School, Bokaro Steel City in 1994

2-Completed 12th from Delhi Public School, Bokaro Steel City in 1996

PROFESSIONAL QUALIFCATION:

1-Completed B.E. (Mechanical) from Mangalore University in 2001 with 1st class.

2-Industrial training in BOKARO STEEL PLANT.

SKILLS:

a)Business Operation, Process Auditing, Business Administration, Business Development

b)Analytical and Reasoning Skills. Strategic Thinking and Problem Solving

c)Financial Analysis, Budgeting & Forecasting, Strategic Planning,

d)Operations, Planning & Budgeting, Costing, Process Optimization,

e)Project Management (Project Initiation, Planning, Scheduling, Monitoring, Commissioning and Handover). (GREENFIELD and BROWNFIELD PROJECTS).

f)Contract Manufacturing,

g)Feasibility Study, Return on Investment,

h)Cost Management (CAPEX & OPEX)

i)Production Planning, Production and Process Control

j)Process Engineering / Improvement

k)Vendor Development, Procurement, Negotiation (Technically) and Demand Planning.

l)Maintenance Managements

m)Materials/Spare Management/Purchase/Logistic/Distributions

n)People Management, Performance Management, Interpersonal Communications.

o)Strong Planning and Monitoring, Resources and Time management

p)ERP Implementation (SAP S4 HANA).

q)Adaptability to Location and Work Environment, Local culture.

WORK EXEPRIENCE:

1)Working with LUCKY INDUSTRIAL MANUFACTURING INDUSTRIES LTD., Nigeria as General Manager Operations from January 2022 to June 2026

AREA OF RESPONSIBILITIES:

Looking after the Manufacturing, Raw Materials, Consumables and Spares Sourcing for the group.

Managing end-to-end manufacturing operations, ensuring on-time delivery, cost control, and quality compliance.

Planning and Monitoring to balance capacity, optimize lead times and meet production forecasts.

Contracts negotiation and preparing service-level agreements (SLAs) with third-party manufacturers to achieve favorable terms and performance metrics.

Monitor performance through regular audits, KPIs, and process improvement initiatives.

Ensure full compliance with GMP, ISO, and company quality standards throughout the manufacturing process.

Development and implementation of supply chain strategies to streamline external production and reduce logistics costs.

Troubleshooting and root cause analysis for deviations in outsourced production.

Plan and execute cost reduction projects through process optimization, supplier consolidation and value engineering.

Maintain accurate demand forecasts and capacity planning.

Operations / Production

Supervision of manufacturing schedules to align with internal production targets.

Improvement in OEE and yield rates at partner facilities through process monitoring and training.

Procurement / Supply Chain

Sourcing, evaluation and onboarding of new vendors for Raw materials and consumables.

Implementation of vendor scorecards and continuous improvement programs with key suppliers.

Quality Assurance / Regulatory

Conduct GMP audits and implementation CAPAs for manufacturing processes.

Ensure all manufactured products meet regulatory and customer specifications.

Project Management / NPI

Work on the processes and costing involved for new products.

Complete documentations before technical transfer and ensure parameters to scale-up of new products.

Manage timelines, budgets, and risk assessments.

Manufacturing Process Areas involved:

a)Stainless Steel, Mild Steel and Aluminium Sheet Metal Works

b)Laser Cutting, Shearing

c)Hydraulic and Eccentric Presswork (Blanking, Stamping, Deep drawing, Piercing)

d)Tools, Jigs and Fixtures.

e)Welding (MIG MAG, SAW, ARC)

f)Powder Coating, Spray Painting, Metallization

g)Metal Fabrication

OVERALL:

a)Audit Compliances

b)Budgeting & Cost Control

c)EHS Operations

d)Lab Operations

e)Maintenance Operations

f)Material Management

g)Plant Operations

h)Process Enhancement

i)Procurement Management

j)Production Management & Planning

k)Productivity Improvement

l)Project Management

m)Quality Assurance & Control

n)Strategy Planning

o)Training & Development

p)Value Analysis / Engineering

q)Vendor Management

2)Working with METALLIC STEEL CENTER CORPORATION LTD, THAILAND as Production Engineering Manager from June, 2019 to December, 2021.

AREA OF RESPONSIBILITIES: Multiple Manufacturing Locations

a)Hot Strip Mill, Skin Pass, Cold Rolling Mill, Batch Annealing, Galvanizing.

b)ERW Steel Pipe from 12 mm to 165 mm. Total eight machines, Slitter of 16 mm thickness / 2200 mm width, Cut to Length 25 mm, Formed C Section / Channel

c)Greenfield project of 19 Stand Continuous Bar Mill capable of sizes 8 – 40 mm, Angles, Flat Bar, Channels. Future plan for Melt shop, caster and wire rod mill (Feasibility work started)

d)Sheet Metal Works, Press Work, Flat Bar, Formed C Section / Channel, Sheet, Slit Strip, Strap Strip, Buckle Making Machine.

RESPONSIBILITIES: Engineering, Operations, Projects and Maintenance (Operations of four Manufacturing Units).

I am responsible for the Operations, Engineering and Procurement activities of manufacturing units within the group.

Responsibilities:

Setting the operation targets based on machine capacity,

Analysing the operational data every day and working on the deviations.

Checking for the need of modification in process or technology to enhance the quality and productivity.

Preparation of engineering details for new project (Modification or new process line).

Preparation of details on investment, return on investment.

Preparations of Capex and Opex for new projects.

New Product development and implementation.

Preparation of Maintenance Plans and Execution.

Root cause analysis,

Spare Management, Time Management, Manpower Management

Procurement:

Vendor development

Negotiations based on technical processes.

Ordering, follow ups and dispatch monitoring.

I represented the company for import procurements.

Projects:

Actively working for the expansion projects.

Worked on data collection and suggesting the Business needs.

Overall mapping of the layout for factories.

Making structures and KPI’s, creating SOP.

Implementation of SAP S4 Hana.

Led Greenfield and Brownfield Projects.

Preparation of RFQ and floating of Inquiries.

Preparation of specifications and scope of projects.

Complete Project Management lead.

3)Worked with PROTO ENERGY LIMITED, Nairobi, Kenya, as Operations Manager (Operations, Maintenance, Projects, Procurements and Stores) from May, 2017 to December 2018.

The company is one of the largest manufacturers of LPG Cylinders and LPG suppliers, which deals in domestic as well as bulk LPG and Conversions with complete turnkey solutions. With Brand Name PROGAS.

The Cylinder manufacturing facility is of latest technology and one of the high-speed production lines.

Area of Responsibilities:

a)500 MT Blanking Press (Double die).

b)320 MT Deep Drawing Press with Automated Trimming and Joggling.

c)Submerged Arc Welding for Valve Boss and Body.

d)MIG MAG Welding for Foot Ring and Guard Ring.

e)Heat Treatment furnace (LPG fired).

f)Metallization and Powder coating line.

g)Utilities (Chiller, Compressor, Water Treatment)

h)Conversion Projects execution.

i)LPG Tanks, Vaporizer, Complete Piping.

Responsibilities:

a)Operations, Planning and Budgeting, Costing, Procurements and Material Management

b)Production Planning, Production and Process Control.

c)Meeting KPI's like Machine Utilization, Productivity, O.E.E, Yield, Cost Efficiency and Delivery.

d)Handling day to day Maintenance activities within the plant premises

e)Completed civil work, erection and commissioning of above mentioned equipments.

f)Preparation and Execution of Preventive Maintenance Schedule, Opportunity Maintenance, Shutdown Maintenance.

g)Manpower planning.

h)Coordinating with the suppliers, contractors and within department.

i)Responsible for entire activity within the plant premises.

j)Setting up of Standard operating process.

k)Ensuring safe working, work culture, health and hygiene.

l)Implementation of SAP S/4Hana

4)Worked with STEEL AND TUBE INDUSTRIES LIMITED, KAMPALA, as Plant Manager (Operation, Maintenance and Projects) from December, 2014 to May, 2017.

Area of Responsibilities:

a)TMT Rolling Mill (8 mm to 32 mm).

b)ERW Tube Plant (12 mm to 127 mm Diameter).

c)Wire Drawing, Wire Galvanizing and Wire Weld Mesh Plant.

d)Expanded Product Plant.

e)Fabrication and Erection of Steel Structures.

Responsibilities:

a)Handling day to day Operational activities within the plant premises.

b)Completed civil work, erection and commissioning of above mentioned equipments.

c)Preparation and Execution of Preventive Maintenance Schedule, Opportunity Maintenance, Shutdown Maintenance.

d)Manpower planning.

e)Coordinating with the suppliers, contractors and within department agencies.

f)Responsible for entire activity within the plant premises.

g)Setting up of Standard operating process.

h)Ensuring safe working, work culture, health and hygiene.

5)Worked with KALUWORKS LIMITED (COMCRAFT GROUP), Mombasa, Kenya as Technical Manager (Head of Department) for Mechanical (Maintenance and Projects) and General Stores from April, 2012 to December, 2014.

Area of Responsibilities: Installation, Commissioning, Maintenance of

a)Melting Furnace of 25 MT capacity and Holding Furnace of 14 MT. (AIF, India)

b)Twin Roll Continuous Caster. (FATA Hunter and Zhoushen)

c)4 Hi Cold Rolling Mill. (FATA Hunter)

d)Slitters and Cut to Length.

e)Blanking Presses.

f)Corrugator and Roll forming.

g)Utilities (Cooling Tower, Fork Lifts, EOT Cranes).

h)Implementation of SAP R3

6)Worked with HINDALCO INDUSTRIES LIMITED (ADITYA BIRLA GROUP), Hirkud, Orissa, as Manager (Mechanical) from May 2008 to April 2012.

AREA OF RESPONSIBILITIES: Cold Rolling Mill

The Cold Rolling Mill is 4Hi Single Stand Non-Reversing Mill (Coil Width of 2100mm) supplied by Achenbach (Germany).

RESPONSIBILITIES:

Project Coordinator and Mechanical Incharge for Cold Rolling Mill

Technical Evaluation & supplier selection,

Review of vendor drawings & documents,

Kick – off Meeting coordination,

Technical Contract preparation and sign-off,

Coordinating with consultants & vendors,

Review and preparation of drawings, piping plans,

Freezing of Technical Specifications,

Reviewing the Layout and Drawings,

Co-ordination with the internal departments, Equipment suppliers and Engineering Consultant,

Planning and Execution of Erection and Commissioning of Equipments,

Co-ordination with other agencies for smoothly unloading of Equipments, shifting of Equipments, erection and commissioning of Equipments.

Detailing and Purchasing of Steel Sections.

Fabrication, Sand Blasting, Painting and Erection of Steel Structures.

7)Worked with TATA STEEL (Formerly Tinplate Company of India Limited) as Assistant Manager in Mechanical Maintenance Department from February 2002 to May 2008.

AREA OF RESPONSIBILITIES: Maintenance of Cold Rolling Mill

a)6 Hi Cold Rolling Mill from SMS Demag, Germany.

b)Steel Structures.

c)CR Slitter and CTL.

d)E.O.T. Cranes.

RESPONSIBILITIES:

a)Reliability Based Maintenance.

b)Preventive and Predictive Maintenance Planning and Execution.

c)Why Why Analysis and Root Cause Analysis for all the Mechanical breakdowns

d)Opportunity based Maintenance Planning and execution.

e)Shut down Planning along with Resources Planning and execution.

f)Joint Inspection and Compliance.

g)Spare Management.

h)Manpower Planning. (All Three Shifts and ‘G’ Shift).

i)Training of the people in-house and outside.

j)Fabrication and Erection of Steel Structures

HYDRAULICS & PNEUMATICS EXPOSURE:

Hydraulic Pumps, Hydraulic Motors, Hydraulic and Pneumatic Valves, Understanding of Circuit Diagrams, SOP for Installation, Commissioning and Maintenance.

TRAININGS:

a)Trained in Industrial Hydraulics by Rexroth Limited.

b)Trained in Rolling Mill Bearing Selection and Maintenance by Timken India Ltd.

ERP: Implementation of SAP S4HANA.

Implementation of SAP R3

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