In-charge Mechanical Maintenance
National Cement Factory
مجموع سنوات الخبرة :37 years, 5 أشهر
Mechanical, responsible for Cement Mill & Finished Product Dispatch areas.
Job Profile:
1. Ensuring availability of all Equipment in Raw material Transportation, Clinker Grinding stations, Cement
storage and Dispatch sections.
2. Technical Manpower and other Resource Planning and Training & Certification.
3. CAPEX Planning & Execution for developmental / capacity enhancement Projects
4. Ensuring implementation of Third party services through AMC’s and Condition monitoring program as
per Plan.
5. Coordination with other departments (Production & Quality and Dispatch) and avoid interferences.
6. Ensuring daily/weekly/monthly inspections of equipment carried out as per PM Plan/Schedules through
C-Works system (Computerized Maintenance Management System) / SAP-PM
7. Ensuring implementation of preventive maintenance & Lubrication routines with minimum backlogs.
8. Ensuring periodical Inspection of all Tools, Tackles, material handling and safety related equipment by
safety accredited third party and certifications.
9. Coordinating with Production for major modifications / corrective maintenance activities
10. Inventory planning and control, spares purchase follow-up through SAGE System coordinating with
Procurement Dept and ensuring critical spare parts availability.
11. Ensuring systematic execution of analysis of Lubricates.
12. Evaluating the maintenance personnel performance through the standard skill matrix.
13. Annual Maintenance Budgeting and monthly Cost monitoring in coordination with Finance.
14. As per IMS(Integrated Management Systems, comply with regulations in
a) QSSE(Quality, Safety, Security, Environment & Social) Hazards Identification & Risk analysis
b) Safety Norms adherence as per Abu Dhabi Regulations AD-EHSMS
c) As part of QMS, ensuring quality standards & documentation and participate in External Audits as
per ISO 9001, ISO 14001:2004 & OHSAS 18001:2007.
15. Achievement of maintenance targets by monitoring through KPI Performance indicators
16. Participation in Management’s drive in implementation of Best Practices in all functional areas.
List of National Cement Factory Main Equipment:
2 No.s of CEMTEC cement mills :- 144 TPH each with total Grinding capacity:-2.5 million tons per year
Mill Drive motor capacity :- 5700KW (AC)
Chain type Bucket Elevators X 2 no.s of 500TPH for cement mills recirculation of KOWEY make
One Chain type Bucket Elevator. & one Belt type Elevator of 180TPH for mills product Silos Feeding
FLSmidth-EEL Rotary packer:-110 TPH (EEL) - 1 No
With Truck Loading M/c (EEL) - 2 No.s
And one Belt type bucket elevator (EEL) of 180 TPH cap.
Bulk loading -4 X Loading Spouts(EEL Make) - capacity: 800 TPH
PLC:- S7-300, S7-400 (Siemens) for Mill Operation
Raw material & finish product transportation Belt conveyors, Air-slides with de-dusting bag filters, etc
Mills venting Bag filters and Air Separators for Mills with Bag Filters X 2 (CEMTEC)
Air Separators for Mills with Bag Filters X 2 (CEMTEC)
Weigh Feeders (Hasler make) with belt conveyors for Mills feeding with Clinker, limestone, slag &
gypsum
Main Achievements / developmental Activities done:
1. Retro-fitting of two Chain type bucket elevators at Mill discharge (re-circulation) and one Belt-
type bucket elevator in place of chain type elevator for Silo feeding (final product)
2. Re-conditioning and overhauling of Cement Silo.
3. Installation of an additional bulker Loading system and Big-bag loading unit
4. Erection of an additional Truck loading Bay including
a. construction of loading bay, civil and steel structures
b. Installation of truck loading m/c and bag diverter
c. Extension of existing belt conveyor
5. Inter-linking of the two mill lines to ensure mills operation even in case of breakdown of any of the
Silo feeding Bucket Elevators
Job profile at our Chennai Grinding Unit of Zuari Cement:
As Manager-Mechanical & SAP-PM, I was totally responsible for
a) New Plant commissioning, plant modification/corrective activities
b) Heading Dispatch operations in packing plant with 2 packers & 4 Truck loading m/c’s.
c) Managing Contracts in Liaison with Purchase dept regarding Loading Contractors
d) Overall Mechanical Maintenance Activities in Cement mill & Packing Plant of the new unit,
e) Effective SAP-PM implementation and training to existing staff of all departments.
SAP Core User in PM/PS/HR Modules)
Managing Preventive Maintenance Planning & Execution through SAP-PM
Training of maintenance dept users in PM/PS/HR modules in their respective functions in our
three different plants
Monitoring end users functioning in the processing of maintenance Orders, Notifications, PRs,
Workmen Time Confirmation through CATS
As Core-user, responsible for creating, maintenance, review & updating of Master data for
plant functional locations, equipments, yearly WBS Projects & Elements, HR data for internal &
external manpower /service contractors
Capex Planning, Creation of WBS Structures & Elements for all new Expansion Projects along
with all other PM related master data
Implementation of SAP-PS Module in Oct 2007 (Project/networking systems) in Bergamo,
Italy.
* Implementation of MDM (Master data Management) through M/s CAP Gemini in Italy during
After independently handling the Erection and Commissioning of two Cement Mills, 4 Cement Silos, Packing Plant, etc., (As part of Zuari Expansion Project for capacity upgradation from 1800TPD to 5500TPD) as explained in the previous experience below,
I was heading the Maintenance of Cement Mills & Packing Plant sections inclusive of material handling equipment in these areas.
Job profile during Plant Maintenance
* Planning & execution of preventive & breakdown maintenance jobs
* Shutdown jobs planning & execution
* Manpower planning & work-orders preparation
* Materials planning, purchase requisitions processing & PO’s follow-up,
* Material stock levels checking, incoming material quality checking
* Modifications & developments jobs
* Annual maintenance cost planning & Budget preparation
* Ensuring house-keeping & compliance of Safety Practices as per
International Group Rules
* Co-ordination with other departments in day-to-day activities
* Involving in Kiln shut-down activities
From Jan-1998 to April 2001, as Senior Engineer
During the plant up-gradation from 1800 TPD to 5500 TPD, I was Project In-charge for Erection & Commissioning of:
• Two no's of Cement Mills: FLS Make, 110 TPH
• Four no's of cement Silos & cement extraction systems
• Packing Plant comprising of 4 no's of Electronic Packers of Ventomatic Make, Italy
• Two no's. of Truck Loading m/c's of EEL make
• Eight no's. of Wagon loading m/c's of EEL make
• Material Handling Equipment like Belt conveyors, Bucket Elevators, Screw conveyors and
Air-slides.
• Electrostatic precipitators & dust collectors
From Nov-1996 to Jan 1998, as Senior Engineer
Responsible for limestone crusher section having
an L&T made Limestone Impact Crusher with 120 TPD crushing capacity.
Secunderabad, involved in Re-treading of 2-wheeler & 4-wheeler tyres.
Job Profile: Planning & execution of Production & maintenance activities for equipments such as
coal fired boiler, tyre buffing m/c's, hot-cured & pre-cured moulds
manufacturers of HDPE woven sacks.
Here, I was looking after maintenance of equipments such as HDPE Tape extruders, Auto tape
winding m/cs & vertical power looms, plant utilities like pumps & compressors.
Job profile: Planning & execution of preventive maintenance schedules, breakdown maintenance etc
Notable Merits:
* Successful Retro-fitting of Bucket elevators, bulk loading system, packing plant extension with
extra truck loading facility at the present Unit.
* Erection of cement Mills, Silos, packing plant during Zuari plant upgradation
* Successful implementation of SAP-PM Module through M/s Wipro in Bangalore during SAP