Production Manager
GULF STEEL WORKS
Total years of experience :29 years, 9 Months
• Plan efficiently and optimize the Plants’ resources to achieve targeted productivity working within or below budgeted Cost of Projects and meeting the Monthly financial Targets of Net Revenue and Profit. Representing the Company and enhancing relation-ships in dealing with Clients, Third party Inspection Agencies and Consultants.
• Fabricating and Delivering the finished Structures & its accessories to customers as promised, ON TIME IN FULL (OTIF) by planning, monitoring and controlling operations of the plants in all production and related activities.
• Analyzing and implementing innovative method and improving Process flow to include Capabilities for growth. Co-ordinating with Procurement & Stores and ensuring adequate supplies of Raw materials and Consumables are made available for the Plants to meet production targets.
• Conducting review with Section Heads and Ensuring Plants’ Operations are meeting with Company’s Quality Policy, Vision & Mission Statements and Core values through frequent Communications, training and Developments of Employees that Company’s Products and Services conform to International Standards.
• Meeting with Production Engineers and delegating works to subordinates for continuous improvements in increasing Productivity of Direct Operations, minimizing off-cut, scrap, excess steel usage, minimizing consumption of Welding & Paint consumables and targeting the consumption within/below budget and saving cost; Quality Engineers to detect the defect and note the trend and improve Fist-Time-Right in Internal & External Inspections.
• Overall Supervising and guiding team members regularly monitoring & expediting pro-duction both in-house and Sub-Contractors, Galvanizers and Dispatch to ensure compliance with plan. identifying deviations from plan & discuss respective Section In-Charges to take corrective and preventive actions to avoid recurrence of such delays or deviations.
• Ensuring sufficient addressing to Production Personnel and Protecting them through: providing safe working conditions, reducing occupational risks related to the performance of their duties by maintaining compliance with all the applicable HSE Le-gal/Regulatory requirements.
• Liaising with HSE & Quality Department for the preparation and publishing of Project Safety and Quality Manuals to ensure Company’s Health, Safety & Environment are complied with.
• Co-ordinating with Dispatch Department and communicating the tentative manufacturing/inspection and Delivery schedule of running projects. Planning of dispatch as per site erection sequence to avoid any delay during site erection at later stage and monitoring the dispatch on daily basis as per plan.
• Developed In-house ERP Production Control System (SSIMS) with IT department for tracking the Consumption of Fabrication and Coating Manhours, daily Job allocation and production tonnage at individual station from Drawing issuance to Delivery of final Products.
• Conducting Root Cause Analysis (RCA) on Internal and External NCR’s of the Inter-division and eliminating the causes by developing solution recommendation and implementing & observing the recommended changes to ensure its effectiveness,
Major projects executed
Fabrication, Supply and Delivery of
• 25800 MT Gas/Steam Turbine Buildings, Equipment Platform Steel structure and Misc.steel to Hyundai Heavy Industries for SAUDI ELECTRICITY COMPANY’S Riyadh, Jeddah and Shuqaiq Power Plants.
• Fabrication, Supply, machining & Delivery of Compressor Base Plates single unit weigh-ing 40ton 27 Pcs, manufactured first of its kind in Saudi Arabia to Saudi Aramco client GE-BAKER HUGHES, Damam.
• 10000 MT Basra International Sports Stadium Complex Steel structure to Al-Jibouri Contracting Company, Iraq.
• 4000 MT Raw Sugar Storage Facility Building Steel Structure to TSK, Saudi Arabia for Durrah Sugar Factory, Yanbu.
• 5800 MT Pipe Racks and Pipe Supports Steel Structure to PETROFAC for SAUDI ARAMCO FADHILI PROJECT, Jubail.
• In-charge of overall Production system, planning and distributing fabrication activities with the focus on optimum utilization of operational resources. Effectively supervising the Shop floor and monitor-ing & motivating a team of 3 supervisors and 100 workmen achieving scheduled project targets.
• Emphasizing on minimum wastage of materials & manpower and inculcating the theme on work-men at every stages of manufacturing process. Constantly monitoring the process to avoid mis-takes and repetition of work.
• Reviewing shop drawings, following up material procurement, identifying and providing solutions to process problems. Preparation of Job, Process & Procurement status documents. Evaluation of Manpower, conducting interviews for hiring employees and selecting talented individuals.
• Preparing BOQ based on client supplied drawings and providing preliminary material/manpower breakdown for costing to Marketing/Sales department for bidding new projects & Equipments. Inter-acting with senior management on project status and Design department on technical issues.
• Ensuring Quality measures compliance by maintaining appropriate requisite documenta-tion/records. Imparting training to all workmen pertaining to quality implementation and compliance. Planning and conducting Internal Audits at regular intervals to maintain standards.
• Familiar with ASME, API650 and other international codes, prepared, guided CAD operators in preparation of drawings for Pr. Vessels, storage tanks and other equipments. Directing the fabrica-tors in material lay out & fit up with geometric and trigonometric calculations.
Major Projects executed
Developed, prepared Drawings, procured all materials and manufactured 15 Aluminium Bulker Trailer worth SR 3.4million in a record period of 15months with a small team of 20 Workmen for ARASCO TRANSPORT, Dammam and HADCO, Hail.
Fabrication of Ø2.2 x 70m long Chimney for SAUDI CEMENT, Riyadh thro’ Saudi Wiemer & Trachte Ltd.
• Supervising and ensuring correct implementation of the project quality plan & procedures and pro-ductivity, executing the project in conformity with work program at site. Mobilization & demobiliza-tion of site crew and eqpts.
• Work preparation and planning of erection activities under controlled conditions as per shop draw-ings, specification, and work plan and contract requirements. Double checking the pre-fabricated items with approved shop drawing before installation.
• Giving the daily instruction to foreman in accordance with the work plan. Monitoring the progress and preparing reports actual Vs plan and forecasting completion. Identifying necessary overtime requirement for the workforce and preparation of time sheet and job accomplishment and managing site documentation.
• Ensuring safe working environment and controlling the use of materials & manpower avoiding wastages. Requesting materials, consumables, tools and equipments well in advance from Head of-fice.
• Co-ordinating with client for inspection and obtaining approval for completed activities for claiming progressive payments. Report to Project manager and providing Job status and getting clarifica-tions on technical issues.
Major Projects executed
Fabrication & Erection of 20, 000 ton capacity flat storage Ware house and other Steel structures (600 ton) for a major upgrading of Arasco Bulk Feed Storage & Handling facilities at KING ABDUL AZIZ PORT, Dammam.
Supervision of Erection of Ø9 x 7m High One way Water Storage tank for SWCC Hofuf Water Transmission Systems, Hofuf through Al-Rashid Hak Consortium.
Damage assessment & Repair of De blend Ø30 x 20m High Water storage Tank roof and bottom plate at SWCC, Al-Khobar Plant.
• Preparation of Quality Assurance Plan covering evaluation of the manufacturing procedures, and definition of inspection criteria for each stage including testing the final product. Monitoring the stages of manufacturing process and achieving the Quality requirement specified in QAP.
• Establishing WPS, preparation of PQR and training welders and coordination with Inspection Agency and qualifying welders. Preparation of weld plan and carrying out inspections of welds at all stages. Conversant with various material of construction, welding technology and welding parame-ters for all weld joints and deciding NDT requirements. Provides support to Shop floor on welding related to issues and sourcing & procuring welding consumables.
• Calibration and operation of all testing equipments such as Pr.gauges, Vernier caliper, Micrometer, Bore gauges Dial gauges and measuring tape. Conducting, witnessing Hydro test and NDT. Carry-ing out inspection on Sand/shot blasted equipment structures and conforms surface preparation to comparators. Inspection of painted structure/equipments for required DFT.
• Preparation of Quality Control documents such as QAP, WPS, PQR, MTC, Dimensional reports, Non-conformance reports, Welding & NDT reports. Ensuring all specified standards are available for reference and observing their requirements.
Major Inspection carried out
Fabrication of Coil Build Ø7 x 4m H Phosphoric Acid Storage tank and Ø5 x 3m H Clarifier tank and other Tank Farm area tanks and Inspection of Ø10 x 10m high Raw acid Storage Tank at ARCHEM, Dammam.
Fabrication & Inspection of Ø3 x 12m high Silos - 24 Nos and its supporting structures for ARASCO FEED MILL, and SS304 & ALLOY20 Tanks for ARASCO GLUCOSE Plant, Al-Kharj.
• Supervision of erection of FILTRATION PLANT & EQPT. in CAUSTIC SODA PLANT based on membrane cell technology. Commissioning of the same plants & Eqpts. Offering successful per-formance run meeting all committed guarantees. Mobilizing & managing site crew. Co-ordinating with clients, smooth & timely completion of site activities. Attending site review meetings and preparation of site progress report. Preparation of COMMISIONING REPORTS for future reference. Servicing & trouble shooting of plants & equipments supplied by us.
Major Plants Commissioned
1. FILTRATION PLANT, biggest indigenous plant in the country so far, in 350TPD capacity CAUSTIC SODA plant for Mardia Chemicals Ltd, Ahmedabad.
2. FILTRATION PLANTS for CAUSTIC SODA plants of
a) M/s Century Chemicals Ltd, Bombay, b) M/s TATA Chemicals Ltd, Gujarat, c) M/s N.R.C. Ltd, Bombay, d) M/s Kothari Sugars & Chemicals Ltd, Pondicherry.
• Development of vendors for fabrication of various equipments like Pressure vessel, Heat ex-changer etc. Planning & scheduling of fabrication activities to ensure timely completion of the equipment. Preparation of BAR CHART and co-ordinating between the works. Conducting NDT / STAGEWISE inspection of various equipments. Carrying out final inspection and issuing release note for dispatch and preparation of complete inspection docket
Major inspection work carried out
Inspection of fabrication of Pressure vessels designed as per ASME code, such as 1) SS/MS REACTORS with mechanical seals. 2) Heat exchanger of various type in different M.O.C”s. 3) 12 nos of Brine Polishing filters of different sizes, 3) 4 nos. of Brine Polishing Filter of 60m3 area, biggest of its kind in India so far. 5) 18 nos. candle filter in varied M.O.C’s.
DIPLOMA IN MECHANICAL ENGINEERING
DIPLOMA IN MECHANICAL ENGINEERING