SUDHANSU S. MOHANTY Mobile: +91 – 9836802225 Email: [email protected]
Job Objective
Seeking senior level assignments in Project Planning/ Plant Engineering/ Operations/ Maintenance with a frontline manufacturing set up. Professional Profile
A Mechanical Engineer with over 17 years of rich experience in Operations/ Maintenance, Project Execution, Erection, Testing & Commissioning, Contract Finlisation in the manufacturing Industry. Presently working with Aditya Birla Nuvo Ltd and is posted in Rishra Works as GM (Engineering & Projects). Adept at planning & execution of projects for plant set up, plant expansion, business process re engineering, modernization and installation / commissioning of equipments. Proficiency in designing maintenance (preventive, predictive & systematic) strategies, procedures and methods; diagnosing breakdown problems; monitoring and controlling maintenance costs in the Industry. Expertise in Vendor Development, Work Order Contracts, Materials Management, Maintenance and Supplier Quality Assurance & resourceful in managing, planning & maintaining large inventories. Proficient at developing cost effective vendors for procuring materials, spares and consumables & experienced in efficient spare parts management and taking cost saving initiatives. Well conversant in planning & scheduling effective maintenance schedule & taking cost-saving initiatives to optimise efficiency of machines to enhance productivity. Familiar with national & International Codes. Highly proficient with MS Office and MS Project / Prima Vera plus strong drafting skills with AutoCAD / Catia v5 and Pro Engineer and good at precise report. An effective communicator with strong analytical, logical, problem solving & organizational abilities. Familiar of working in the ERP Environment.
Core Competencies
Project Planning & Management Handling project activities involving working out various requirements with respect to utilities, machines, manpower & monitoring overall project operations for ensuring timely completion. Ensuring that site operations are carried out smoothly with erection, commissioning & procurement operations. Developing financial projections, preparing budgets and performing extensive project costing. Managing resources to perform project activities in cost effective manner. Dealing with consultants/ licensors/ statutory bodies for compliance of requirements. Commissioning/ Testing/ Quality Handling erection, commissioning, inspection tests of numerous plants & equipments to ensure completion of projects within stipulated time/ cost parameters for determining the effectiveness of equipments / plants. Providing technical inputs & developing master specifications with needs assessment. Implementing latest tools like TPM, TQM, 5S and executing process enhancement projects. Conducting Internal Audits and ensuring compliance to ISO 9000: 2000 & ISO 14000 standards & HSE Policies. Operations & Maintenance Planning and effecting preventive maintenance schedules of various machineries and instruments to increase machine up time and equipment reliability. Proactively identify areas of obstruction/breakdowns and take steps to rectify the equipments through application of trouble shooting tools. Executing cost saving and energy saving techniques/ measures and modifications to achieve substantial reduction in O&M expenditures and work within the budget. Process Enhancement & Cost Saving Initiatives Identifying areas of improvement and recommending process modifications and equipment calibrations to enhance operational efficiencies of the systems. Reviewing the operational practices, identify the areas of obstruction/ quality failures and work on system and process changes for qualitative improvement/ energy conservation. Implementing inventory control measures to reduce obsolete stock, keep tab on slow-moving items and achieve reduction in inventory management cost. Undertaking Value-Engineering initiatives at the suppliers end to reduce cost of rejection of the material supplied. Inventory Management Replenishing of stock items by raising purchase indents and delivery advices & scrutinizing purchase indents for spare parts of equipment. Carrying out Inventory management of equipment with review systems ROL/ROQ. Conducting Inventory analysis A/B/C, X/Y/Z, lead time, vendor rating and development with regular inventory verification of stock items. Governing the inventory function so as to curtail inventory-holding expenses and adherence to the minimum inventory level to minimize wastage. Monitoring disposal of surplus items & hazardous waste such as used oil, catalyst plus surplus and scrap items. Vendor Development/ Procurement Identifying & developing cost effective vendor/supplier base for cost effective procurement of materials, spares and consumables.
Page: 1 / 3 Preparing Annual Rate Contracts with vendors for stockable items and for work order indents and timely renewal of contracts after complete review. Assessment of performance of the vendors based on various criterions such as quality improvement rate, timely delivery, credit terms etc. Contract Management Preparing contract budgets & ensuring that the cost budget is not exceeded. Preparing & floating of tenders to contractors, evaluation of offers, techno-commercial discussion & finalisation of contract in view of project schedule. Carrying out the settlement of techno-commercial disputes/ clarifications with clients during execution of project.
Organisational Experience
Since May’08 with Aditya Birla Nuvo Ltd. as General Manager (Projects & Engineering). Under the flagship of Aditya Birla Nuvo Ltd. there are two businesses textile & insulator works at Rishra (Hoogly) & Insulator works at Halol (Gujrat). As GM (Projects & Engg) I am entirely responsible for it’s expansion plan and keep plant cost effective by introducing new technology and new maintenance strategies.
Career Growth Path Tenure Designation May’08 onwards General Manager (Engg. & Projects), Aditya Birla Nuvo, India Dec’06 to Apr’08 AGM (Projects), Global Steel Holding Ltd. Serbia / Bulgaria Jan’05 to Dec’06 Chief Engineer (Modernisation), Tata Refractories Ltd., India Jan’96 to Dec’04 Projects Manager, Tata Refractories Ltd., India Sep’93 to Dec’95 Materials Manager , Tata Refractories Ltd., India Aug’90 to Sep’93 Maintenance Manager, Tata Refractories Ltd., India Significant Achievements; Completion of feasibility report for newly coming up thermal power station at Prestina; Kosovo for supplying power to galvanized plant. Revamping and reviving of dormant Magnohrom DOO plant at Serbia to it’s 90 % capacity to achieve the designed production capacity. Conceptualized and successfully modernized of one 20 years old 1600 T hydraulic press to regain it’s efficiency upto 90%. Indigenously designed cost effective 5 TPD Electric Arc Furnace for Fused Magnesite (FM). Once commissioned saving per MT of FM shall be to the tune of € 15 000 per month over imported FM. Successfully converted one no of 35 mtr cooler to 7000 C drying furnace for Resin Bonded Magnesia Carbon bricks. Augmented TRL plant capacity by 60000 MTA (Silica - by 24000 MTA, Mono - 36000 MTA) by 2006~07 within a budgeted amount of Rs. 80 Crores. Accountable for the Entire Modernisation Program of Tata Refractories budgeted at a CAPEX of 282 Crores, in line with Co's mission to achieve 1000 Cr in next 10 years. Entirely accountable and successfully executed following major projects in following categories : Infrastructure & Logistics Training Center: A state of art 60 sitter and 4 room aluminum sheet cladding training center at Tata Refractories Ltd. And double storied 1000 seating capacity Canteen, Café with Training Center at Aditya Birla Nuvo. Hospital: Modernized and modified the existing 25 bed exiting building to a 72 bed with ICU, modernized Operation theater at Tata Refractories Ltd. Finished Good Yard: Designed and constructed a 30000 MT FIFO storage house with high reach truck for storing finished goods at Tata Refractories Ltd. And 6000 m2 semi circular roof shed at Aditya Birla Nuvo. Expansion Shed: Constructed a 3600 sq mtr entirely concrete shed with semi round roof with flexible drainage system for easy excretion of rain water. New Logistic System: Indigenously designed new logistics including commissioning of 100 MT pit less weighbridges for faster traffic movement and reducing truck detention time from 16 hours to 2 hours. The new logistics is hooked up to on line SAP system and is free of duplicacy entry points. EPC Projects Tunnel Kiln for ceramic Insulators: 76 mtr long tunnel kiln with technical know how from Wistra; Germany at Aditya Birla Insulators. This will increase firing capacity by 12000 MTA. 132 KV Sub Station at Tata Refractories and 33 KV Sub Station at Aditya Birla: Timely completion of approval of design to required approval for higher contract demand certification from governing authority. Successfully completion of procurement to commissioning of HT transformer. 110 MW Thermal Power Plant Feasibility Study: Completed the feasibility report for newly coming up 110 MW Thermal Power plant at Prestina; Kosovo. Plant is comprising of 2 nos of 55 MW Turbo Generator (hydrogen cooled) & three nos of coal based fluidized bed high pressure boilers (220 Tons / Hr, 535 0C, 96 kg/cm2). Automated Monolithics Plant: A 46000 MTA fully automatic controlled plant over an area of 600 m2 and designed to be operated with only 6 persons. The plant has pneumatic conveying system and inclined mixer machine with fully automated control system for RM feeding and final product stacking. Silica Tunnel Kiln: Designed and commissioned 180 mtr long Tunnel Kiln with technical know how from Reidhammer; Germany. It is the first of its kind in India having designed capacity of 72 MTD. With 90 % yield kiln shall cater to a demand of 24000 MTA. This is the only tunnel kiln in Indian refractories industry to fire Silica bricks. Dolomite Tunnel Kiln: Completed erection and commissioning of 76 mtrs long and 72 TPD Tunnel Kiln built with technical know how from Reidhammer; Germany. Rotary Kiln: Successfully supervised erection and commissioned 110 TPD 2nd Rotary Kiln supplied from L & T.
Page: 2 / 3 Dolomite Expansion: The earlier capacity was doubled to 80000 MTA from 36000 MTA by addition two nos of 2000 T Hydraulic presses, one jacketed 2000 ltr inclined mixer machine and indigenously designed state of art FIFO storage house of 20,000 tonnes capacity. Gasification Plant: Installation of 3 nos of Extended Shaft Searsole Gas Producer having capacity of 24000 Nm3 / day each within record period of 6 months. Flow Control modernisation: Revisiting the entire lay out to augment the capacity to 3600 MTA by adding new inclined mixer machine, hydraulic presses and re-drawing new logistics. On line packaging system for Dolomite: Conceptualised and commissioned on line packaging system for Dolomite with a capacity of 250 pallets per day within a constrained budget of Rs.5 Crore. Automating loading and Unloading of cars: Conceptualised and completed design of entire robotics system for handling of delicate and hot bricks coming out of kiln at Dolomite stock yard. Completed 180 mtr long Silica Kiln's Foundation within record time of 25 days. Parallel planning and control of 6 projects related to drying of Silica and High Alumina bricks, new presses (SACMI 1600 MT), new gas producers (72,000 nm3). Successfully met 85% of project deadlines without overrun. Conducted project activity definition, sequencing, duration estimating, schedule development & schedule control. Prepared Silica Modernisation (Rs.26 Crore) and Dolomite Expansion (Rs.78 Crore) project documents including scope definition, project justifications, calculations, drawings and specifications. Skilled at resource planning, cost estimating, cost budgeting and cost control. Operated project planning and control software for detail tracking of Gantt charts, S Curve and critical route analysis of project activities. Recommended strategies to improve project progress and reduce negative impacts in schedules and budget. Developed engineering designs, specifications, cost & time estimates and operational studies. Administered engineering contracts valued Rs 11 crore; reviewed consultant's (M N Dastur & Co.) submitted work products to ensure compliance with proposed design and material specifications. Was the Chief of Implementation Group for successful execution of Total Operational Performance by studying the cost base and implementing suggestions to get the maximum benefits. Reduced the grinding cost of High Alumina products by re-designing the flow circuit in consultant with M/s. Vinar. The new grinding circuit has capacity of 48000 MTA and a saving of Rs.234/- per MT. Functioned as the Single window for communication with consultants like M/s. M N Dastur & co for Tunnel Kilns & Rotary Kiln.
Sept’93 to Dec’95 with Tata Refractories Limited, as Materials Manager.
Significant Achievements; Analyzed and recommended strategy for replacing legacy system with e-procurement system. Developed supplier selection matrix for content management and B2B strategies. Developed cost savings database allowing real time reporting capabilities & administered training class to procurement division. Brought the concept of dynamic monthly consumption and dynamic lead into procedure of materials information system to predict 90 % accurate prediction and procurement of spares' requirement (JIT) respectively. Successful procurement of Rs. 5 crores worth project equipment and spares for only Dolomite plant in India. Outsourced operation of front end loader and packaging of finished goods. Introduced the dynamic lead-time of all items for economical ordered quantities predicting the lead time with 95 % accuracy. Designed supplier database accessible through the intranet for the disaster recovery team. Off loaded the non core activities like front end loader and materials handling, maintenance of centralized AC and ground materials packing Commenced professional career with Tata Refractories Ltd, as Maintenance Manager from Aug’90 to Sept’93.
Trainings Attended – Management Training from XIMB, Jamshedpur. – Project TMDC Management from Tata Management Development Center, Pune. – ABC ' Activity Based Costing ' from IIM; Kolkata. – MI (US) 'Operation Excellence' by Prof. Ravi Anupindi from Michigan Business School. IT Skills RDBMS : Oracle (9i, 8.1.x) ERP Tools : Baan III / IV, Baan tools 6.1, AutoCAD, CATIA and Pro Engineer Front End tools : AutoCAD, Inventor suit, Prima Vera, MS Projects & Pro Engineer Academic Credentials
BE (Mechanical) from University College of Engineering, Burla; Sambalpur University with 74% in 1990.
Personal Details Permanent Address : Flat no: 204, B – Block, Keshari Enclave, Nua Sahi, Bhubaneswar – 750 012 Mobile : + 91 – 98368 02225 Date of Birth : 04th April, 1968 Alternate E-mail Id : [email protected]
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