Plant Operations Manager
Econosto Mideast BV
Total years of experience :32 years, 7 Months
Conceived Plant Initialization activities as Capex, Plant & Machinery requirement, Plant Layout, Supply chain development, Quality Manual Drafting, Deployment, Manufacturing Processes.
Supporting Internal Sales team on the technical requirements in projects, product selection & making offers.
Intervalve India Ltd. is engaged in manufacture of Butterfly, Ball, Gate, Globe, Check Valves and Actuators.
As Head of Operations for Butterfly Valve Division, I was responsible for planning, manufacture & meeting invoicing targets. Handled Valve and Valve Automation orders.
Deploy strategy, handled capacity enhancements. Deployment of Best Practices according to Lean.
Development of Triple Offset Butterfly Valve.
Improvement in Layout & Processess- Machinery selection for future products, productivity improvements & product enhancement in Valves & Actuators
Kirloskar Brothers Ltd. is a leading manufacturer of Pumps & Valves in Water, Irrigatio, Oil & Gas, Nuclear & allied segments.
• Oriented all sections towards deployment of Lean & Best Practices. Implemented VSM for Gate Valves & BFV with improved throughput time.
• Reduced lead time for execution of Cast Steel Gate, Globe, Check Valves from 16 weeks to 10 weeks. Lead time for BFV & SLV manufacturing reduced to & maintained at 8 & 6 weeks resp.
• Increased & Improved in-house value addition (plant utilization) in manufacture of Butterfly Valve & Sluice Valve. Improved OEE from 56% (Apr 2012) to 63%(Sep 2013).
• Improved On Time in Full Delivery from 69% (FY 2011-12) to 80% (as of Sep 2013)
• Improved inventory performance with RM+WIP reduction by 14 days & Non Moving Inventory reduction of INR 6 Mil.
• New Products Developed- 3.8m BFV (Range Enhancement), Suction Diffuser, Triple Duty Valve, Dual Plate Check Valve, Hydraulic Actuators for Pump Discharge BFV.
• Various Process Improvement Initiatives helped achieve ambitious target for Invoicing (30% growth on FY 2011-12 invoicing)
• Improved relations with workmen & successfully completed wage negotiation in Feb 2013
Virgo Engineers Ltd. is a multinational engaged in manufacture of Valves & Valve Automation systems, with manufacturing facilities in US, Europe, UAE & sales offices throughout the globe.
I have headed Valve and Actuator Division in the capacity of Head- Operations.
Products Handled at Virgo Engineers Ltd.-
API 6A -Casing & Tubing Heads, Adaptors, Flanged Connectors, Valves, Chokes, Tee’s & Crosses, Pipe joints & plugs.
API 6D Ball, Check Valves, Butterfly Valves- Centric & Triple Offset valves
Actuators- Rack & Pinion & Scotch Yoke,
Steam Traps - Float & Thermodynamic Type.
Significant Achievements at Virgo Engineers Ltd. for Valves and Actuator Div.
(Dual Responsibility during Year 2007 to 2010)
• Successfully implemented initial activities that included defining business model, outlining processes, outsourcing strategies, selection of machines, shop floor layout for efficient material movement, effect make or buy decisions, secure key plant & product certifications in the initial period between 2005 & 2007.
• Developed Supply Chain for API 6A Valves & Well Head equipment manufacture, API 6D Ball Valves, Triple offset BFV & Actuators(Rack Pinion & Scotch Yoke).
• Key Inputs to Product Development with specific regards to feasibility, manufacturing costs & operations, tolerances required & possible.
• Developed process layout & fixtures for manufacturing triple offset butterfly & Gate valves. Streamlined & Standardized processes. Deployed process & systems approach, throughout the organization & at vendors end.
• Costing of all products handled & maintained costs under control (Improved Margins)
• Since conceptualization of the unit in June 2005 improved turnover of the division from USD 1.5 Million (2005) to over USD 7.5 Million in the year 2009.
• Implemented Baan ERP successfully.
• Reduced lead time to supply products to customer by over 20%, improved inventory turns to 5 on an average.
• Installed manufacturing capacity of appx. 2000 R & P actuators & 60 Heavy Duty Actuators p.m.
• Handled automation of Ball Valve & BFV with pneumatic & electric actuators.
• Multi-Unit Opertaions Management - Managed Operations of different product lines - Well Head Div., Butterfly Valves & Actuators Division between 2007 & 2010.
• Developed manufacturing for range of steam products- Steam Traps & Strainers.
Procurement of machined components, components for machine tools & process industry.
Costing of Components
Making Annual Rate Contracts
Capital Purchase.
Supply Chain Management & Logistics- Local & Imports, Inbound & Outbound.
Manage Warehouse
Execute Orders for Spares
Purchase & Vendor Development.
Procurement of Basic Raw Materials as castings, forgings & machined components, components for machine tools & process industry.
Procurement & strategies for bought-outs as bearings, paints, valves & fittings.
Develop Vendors for Sub Assemblies & Assembled Finished Products.
Finalise Annual Rate contracts for Barstocks, Metals, Logistics & Freighting.
Sub-Contract activities as all types of conventional & CNC machining, heavy fabrications for projects, assemblies, painting.
Capital Purchase.
Supply Chain Management & Logistics- Local & Imports, Inbound & Outbound.
Manage Warehouse, Packing & Shipment, Inventory planning.
Implement SAP ERP
Procurement of Basic Raw Materials as castings, forgings & machined components, components for process industry.
Sub-Contract activities as all types of conventional & CNC machining, heavy fabrications for projects, assemblies, painting.
Costing of Components.
Make or Buy Decisions.
Capital Purchase.
Product Development, Vendor Development- Valves & Actuators.
Supply Chain Management & Logistics- Local & Imports, Inbound & Outbound.
Warehouse Management, Packing & Shipment, Inventory planning.
My earlier achievements have always resulted in more responsibilities & opportunities
to prove my skills, which to me is the biggest recognition
Reverse Engineering & Drafting of X Ray Tube Housings for Comet, Switzerland & GE Medical Systems, USA
Develop & Test Prototypes.
Develop Supply Chain & Import Substitution.
Quality Control- Deploy Quality Parameters & Inspection Techniques.
courses: TUV Certified Lean Professional
in
courses: Dinesh Dalvi