Production Manager
USG ZAWAWI DRYWALL LLC
Total years of experience :21 years, 4 Months
Highlights:
• Pioneered in commissioning Asia’s one of the largest gypsum mining plant with production capacity of 3 million tons / annum. Largest professionally managed gypsum quarry in the Sultanate of Oman
• Pioneered in commissioning gypsum board production line supplied by GYPTECH with production capacity of 8 million m2 / annum
• Played a stellar role in stabilizing the process within 20 days of plant operation to meet with ASTM standards
• Distinction of enhancing OEE (Overall Equipment Effectiveness) from 47.5% to 96% within a short span of 2 months
• Instrumental in assessing process stoppages and finding root cause analysis
• Pivotal in significantly saving cost by reducing raw material consumption
• Improved the production capacity from 8 to 10 million m2 / annum by analyzing the process and improving CAPEX for debottlenecking the plant
Saved 25% of the total project cost.
Successfully streamlined the project and handed over the same to the younger brother.
Initially mushroom batches were getting failed. Then investigated to find the root cause and provided solution which was cost effective as well as more productive.
Presently Mushroom project is diversified to Balcony Gardening named as “Lovely Garden”.
Vision: To enhance entrepreneurship.
Highlights:
• Pioneered in commissioning gypsum board production line supplied by M/s. DCI Ltd., China and obtaining net saleable yield of 85% within 2nd month of plant operation
• Steered efforts in disseminating classroom training programs to operations team on Safety, 5’S’ and WCM
• Acknowledged for effectively guiding & mentoring unskilled operations team to break through excellence
• Distinction of maintaining safe working practices across the plant
• Appreciated by the management through Certificate/award for showcasing dedication in work and providing all the required assistance in a timely manner
Highlights:
• Steered efforts in developing best behaviour of employees and safe environment while functioning as the head of the plant
• Pioneered in managing & reducing product’s cost by 80% through innovation methods
• Significantly enhanced production & quality of plaster (German Technology) and gypsum board (Chinese Technology) by taking several measures such as optimizing
o Plaster kettle efficiency
o Gypsum board dryer performance
• Successfully implemented & maintained safety culture in the plant by providing training to employees on a regular interval
• Stellar in practicing energy conservation, 5’S’ and achieving production targets of the plant year-on-year basis
• Played a key role in commissioning Chinese Technology Semiautomatic Gypsum Board Production Line of M/s Hebei Lvjoe Machinery Manufacturing Co. Ltd. and secured net saleable yield of 82%
• Instrumental in stabilizing gypsum board plant for production of various board thicknesses from 7.5 mm to 15.0 mm which helped in getting more market share in Gulf and also customer satisfaction increased
• Distinction of visiting in Germany, Switzerland and Italy in 2011 for addressing business meetings on behalf of the company
Received the 5’S’ trophy in inter zone competition held in March, April and May’2009 regularly.
Successfully commissioned Calcination and Board Plants. Achieved 96.5 % Net Saleable yield, within 3rd month of operations.
Follower of SMAT, Lock Out & Tag Out and Work Permit Systems.
Pillar Member for Safety, Focused Improvement as well as Autonomous Maintenance (World Class Manufacturing System).
Effectively handled the plant operation through Siemens PLC and Win CC integrated automation.
Involved in certification of OHSAS-18000 (Occupational Health & Safety Advisory Services).
Completed two Focused improvement projects at SGGIL, Chennai and SGGIL, Wada plants for board damages and centre crack at Inverter.
Many improvements done in maize steeping process to improve Starch yield by 0.5%.
Effectively handled the plant operation for production of Starch, Gluten, Germ, Fiber, Corn steep liquor (CSL) and Dextrose monohydrate.
Primarily involved with senior team for increasing productivity and quality of the products.
Seniors appreciated sincerity and performance in various tasks.
Handled the equipments like Heat Exchangers, Pumps, Valves, Blowers, compressors and Cooling Towers.
Indenting and Procurement of project related materials.
Actively involved in erection of Co-generation project.
Actively involved in installation and Commissioning of ETP plant.
To ensure the successful completion of engineering projects by establishing project timelines and organizing project resources.
To ensure proper Communications and make recommendations to keep everything running smoothly.
To ensure proper water parameters in the ponds.
Testing of Dissolved Oxygen, pH, Alkalinity, Bloom growth etc...
Handled the process of Zinc / Iron Phosphating, Powder coating and Zinc Electroplating
Maximum electroplating batches within limited span were implemented.
Initially lots of product rejection, then tested the plating bath chemical concentrations to meet as per standards also various trails taken in prototype bath for further stability of process.
Seniors recognized the sincerity, hard work and dedication.
BE (Chemical) from K.L.E.S’s College of Engg. & Tech., Belgaum, affiliated to Visveswaraiah Technological University with 72.38%