Manager - Maintenance Workshop
Rockwool India Private Limited (Subsidiary of ALGHANIM INDUSTRIES-KUWAIT)
Total years of experience :31 years, 6 Months
Handling PM, Shutdown & Breakdown maintenance & machining jobs with Tool Room / Work Shop to upkeep DCS-SCADA continuous process plant
=>Fabrication, Welding, Machining
Equipment Maintenance Support for:
Fiberizer machinery,
Flying Saw, Cupola furnace, Conveyers,
Blowers up to 50000 CMH,
Air Compressors, Captive Power Plant,
Cooling towers, RO Plant, Water treatment plants, ETP, Pumps, Motors,
Heat treatment ovens,
Spare parts management, Development
Tool Crib Management
Responsibilities: Fabrication & Machine Shop in-charge, Shutdown projects, Workshop Team of 110 | Reported to PM
Headed Shutdown Maintenance Projects at ALBA Aluminium Bahrain & Al Riffa -EWA Power Plant - Main Gas pipes & supports
Maintenance of Concrete Ready Mix Unit, Machine Shop equipment, fab. of Steel Shuttering for Hidd-URS, Muharaq Ring Road
Erection & installation of equipment for Asphalt Plant Project, structure, machinery, foundation.
Fabrication In-charge of 54 nos. Dumper body 16, 22 Cu.M. & Assembled on Benze Actros Heads trucks (Saudi Arabia company)
Company Profile: Manufacturing ERW/CEW/DOM Precision Steel Tubes, Hollows, Sectional Pipes
Provided Engineering Services department of two steel plants \[1\] ERW/CEW Steel Hollow / Sections Tube \[2\] Precision DOM Steel tubes (mega project).
Headed Maintenance of Tube Mills, Slitting Lines, Decoilers, Coilers, Tube Straightener, Flying Saw, 250KW HF Units, Induction Furnaces, Utility Services
Increased MTTR up to 50% through awareness of good work techniques of CNC repairs in maintenance personnel.
Reduced bearings consumption by 30-40% on Tube Mill by redesigned spindle & bearing selection.
Conversion of original controllers in Demag EOTs with AC drives and 80% improved MTTR & MTBF.
22 nos. Overhead E.O.Ts 32T, 10T, 5T, 2.5T, Gantry, Material handling equipment etc. Demag, Electromech, Improved MTTR of E.O.Ts by in-house designed & developed parts.
Carried out major repairs on Draw Bench and refurbished and introduced in production with select DC Drives-Motor.
Resolved high consumption of bearings on Tube Mill by redesign of spindle and selection of bearings.
Responsibilities: Facilities O&M, Installation, Commissioning Team of 75 | Reported to PM
Headed O&M of Power Plant 10 MW - Caterpillar 3512B x 7 nos., Diesel Storage tank farm O&M
HVAC- York (UK) units Diesel Burners, Refrigeration Systems, Training, Facilities Installation & commissioning
Maximo CMMS- Work Orders management, closing, spare parts ordering, Planning and Scheduling of work and manpower
Company Profile: Mfr. Sulphuric Acid, Alum, Fertilizers, Glass & HR/CR/GI Steel Sheets, Pipes, Roofing Sheets, Z-Purlin, TMT Rods, Wire & Coils
Incharge for Maintenance, Projects & Work Shop:
\[1\] African Ferilizers & Chemicals Nigeria Ltd.
\[2\] Ispat Steel Nigeria Ltd
\[3\] African Wire and Allied Industries Ltd.
\[4\] African Glass Limited
Revamped 1200000TPA of H₂SO₂ Acid/Alum Plant: Piping Fabrication and replacement of static and rotating equipment i.e Blowers, Motors, Boilers, Columns & Chimneys, Process Equipment and AC Drives and DCS controls systems, Captive Power on NG based DG & commenced production.
Erection, Installed & Commissioned, 300Tpd Steel Processing Unit two CTL Lines for GI/HR/CR Sheets, Electrical power & control panels
Implemented PM Program and achieved >99.6% uptime of Captive Power plant 3.5MW NG/Diesel based Generators.
Maintained Reciprocating / screw compressors, E.O.T. cranes, Forklifts, & mobile cranes & 20% increased uptime.
Perfect Production planning as per sales forecast & achieved 100% availability of Finish Goods.
Managed Warehouse & logistics operations for CR/HR/GI/Alu-Zinc Coils, Sheets & Reinforced/ Plain steel wire coils & rods with capacity of 100, 000MT. Monthly stock taking of RM and finish goods.
Stabilized production lines with major maintenance of wire straightening and cut-to-length machines, sheet -cut-to-length machines, Sheet Forming lines resulted 99% un-interrupted and quality production.
Daily Production up to 250MT & Dispatches achieved up to 360T per day, Monthly sales dispatch of up to 6000MT
Trained supervisors and local staff in production, maintenance and achieved %Scrap .
Company Profile: Manufacturing HSS, BiMetal, Carbon Steel Saw Blades and Band Saw, Cutting Tools, Hand Tools
In-charge of Production, achieved 300KM/Month of Bi-Metal Bands by continuous training & TPM activities.
Headed Mechanical maintenance of plant equipment (SPM) for manufacturing and Tool Room Facilities.
Achieved shining quality by introduced N2 gas purging technique in Electric Annealing Furnace.
Designed and built a loading/Off-loading system for 60 coils in-feed systems with 100% product safety.
Reduced nozzle consumption up to 50% by introducing Boron carbide Nozzles and custom built Shot Blasting equipment commissioned in plant.
Reduced energy consumption by selection of VFD air compressors and adherence to service schedule.
Technology transfer from USA to India : Trained in the USA mother plant, and Installed and commissioned Bimetal band saw and hand saw blade product lines equipment. Timely completed project by fabrication of 8 nos. of equipment in India reduced total cost by 1/4th.
Provided engineering support to production for development of tooling, Press Tools, Dies in house saved 35% cost.
Achieved 100% tooling availability by Operation & Maintenance, Calibration of 5Axis CNC machines (SPM) for Tooling Reconditioning.
Implemented visual TPM for each machine and created quality working environment compliance with ISO9001.
Developed vendors for procurement of spares and consumables for product and packaging in India.
Company Profile: Manufacturing of Taper Roller, Cylindrical Roller & Ball Bearings for Automotive, Wind Mills Railways.
Engineering Support for Breakdown and Preventive maintenance of: CNC/PLC based Precision grinding machines for Internal & external ID/Track (Famir International, Italy) & Center Less Grinding (WMW-Mikrosa), National Machinery USA - Solid open die cold heading machines 500T & 750T, Power Presses (Ameteep) up to 500T, Hydro-dynamic spindles, High Speed Gamfoir Italy Grinding Spindles, EOT Cranes, Hydraulics and Pneumatics automation, Shot Blasting equipment.
Heat Treatment Plant, GEC Furnaces-CLC-Tempering-Shaker Hearth, Endo Gas generation plant, Salt bath, LPG storage and ENDO GAS Cracker systems.
Installed, commissioned and O&M of 1000 CFM Reciprocating IR IHE-5 and Atlas Copco GA37 Screw Compressors, Over Hauling of Compressors, Vibration and Noise Analysis, 500CFM Air driers and Desiccant heatless air dryers.
O&M of Chilling Plant for Air Conditioning, Becon 3L3 centrifugal 30HP pumps, Cooling towers, Pipe line work & Insulation, Special Purpose Welding Technology
Implemented of ISO/QS 9001 quality systems and documentation. Conducted Energy Audits and implementation of suggestions. Calibration & Validation of Lifting Equipment & Pressure Vessels as per ASME, DIN Standards.
Reduced 60% coolant oil consumption by effective implementation of Coolant Management System.
Converted of Contactor Logic Systems to PLC control systems, Hydraulics systems replacement with Standard Customised Power Packs.
Diploma in Mechanical Engineering in Year 1991 Major in Power Plant Engineering, Tool Engineering, Refrigeration & Air Conditioning
(HSC) Gujarat Higher Secondary Education Examination Board