Senior Dept Manager-EPC
Ramsis Engineering
Total years of experience :20 years, 10 Months
Since August 2010 Ramsis Engineering, Bahrain Senior Dept Manager-EPC
Role: • Executor-EPC-Contracts/SCM of Refinery, Well manifold/compressor station/WWTP/SS equipments & Tools in On/Offshore.
• Scheduling/managing overall execution strategic plans/ risks (scope/cost/time/quality) / milestones for timely projects.
• Creating HSE regulations of Occupational Health Psychology (OHP), Industrial & Organizational Psychology (IOP)
• Recruiting HSE-Team (Superintendents/Officers), imparting safety induction, workmen permits, training on OHP & IOP, Industrial & Environmental Safety, Inspections / Reviews & executing the safety proceedings like Qualifying for H2S & Confined Space, JSA/Method Statements/Work-Site PTW & Safety approvals for the jobs/workmen/rigging/ equipments.
• Formulating/monitoring QMS for QA Operations, Project Quality Plan (PQP) and Procedure Qualification Record (PQR) under WPS and WQT for Construction/EPC Projects and conducting Quality Inspection & Testing (ITP)
• Setting ITP for executing Inspections and Testing for internal and external agencies of Third Party Inspectors (TPI) like Velosi, LR, IRS, ABS. ITP/Test Sampling coverage for all forming processes like Welding, Piping/leak tests, fabrication, Cable Tests, Instrument Calibration, recertification/ revamping, Stress analysis, hydro Testing.
Significant Contributions
• Excreting to execute many piping/tank/shipyard/rig drilling of On/Offshore Fast Track Projects within time/budget.
• Secured from clients to company additional projects on the basis of excellent services & on-time deliveries of projects
• Motivated to build team competencies systemising SOP, QMS norms, QHSE, QA standards/codes & Client's objectives
Jul '07 - July 10 Pwani Oil Products Ltd., Mombasa, Kenya GM-EPC Projects
• Managed Equipments Engineering Design (FEED), P&ID & MTO with specs/standard, simulating/confirming process design
• Executed EPC Conytats/SCM of Oil Refineries, FA Distillations, Power/Desalination Plants and ETP/WWTP/EPCM of plant/utility equipment (Rotating/Static types), tank fabrication (30000m3), Piping, Electrical/C&I & Civil jobs at EVM (Earned Value Risk Analysis) /Quality Standards. Expertise in P6Scheduling. QHSE, QA & Resources planning & progress reviews/controls
• Optimized oil field project operations, executed AFE components for Start-Up, Workover & Completion programs inspecting the quality standards, norms, methods/practices and contracts.
• Reviewed project progress to avoid risk value assigned/anticipated due to project over-run and adopted the remedial actions
Key Project Handled: • Undertaken EPC Projects in QAFCO Fertilizer Plant & QP (Petrochem), Qatar Onshore/Offshore Projects and Oil Refineries, Chemical, Distillation Plants of Billion USD under Project Division of Manufacturing/Marketing Company of 2000 T/O.
o Project Earned Value Management comprising EPC Operations of FEED & HAZID/HAZOP study, cost analyzed/ negotiated material/equipment purchase, compared/evaluated technical & commercials bids finalization, specific skilled & quantum of manpower hiring, limited equipment/vehicle deputing and highest utilization of all resources/ HSEs
Feb '06-Apr '07 Quality Group Ltd. (Projects Division), Tanzania General Manager-Operations
• Executed EPC project EVM of F&B units, Packaging Units, Tan-Pearch Aqua Units & Rice Mill (100T) Units of $100M.
• Planning the project target and identified various resources to achieve the high quality project at planned cost.
• Successfully achieved the planned production target of 6 M pm/plant bottles of soft drink/juice bottling at the lowest OH.
• Established the benchmark of peak production at optimal manpower, yield of materials and OEE of plant with emphasis on standard quality.
Key Project Handled: • Headed the Projects Contracts/SCM, Engineering, Manufacturing & Marketing Operations of Chemical /F&B Units, Engineering Plants & Machine Tool Division of T/O $400 million.
Jan '03 - Jan '06 GRP Piping Projects (Oil & Gas), Chennai (Strategic Engineering Ltd.) G M - Manufacturing & Projects
• Led Oil and Gas cross country piping projects/contracts & EPC Projects of various GRP pipe manufacturing plants in India.
• Formulated SOP and optimized JIT material plan, resource utilization/OEE & achieved high rate of production and projects
• Monitored QA/QC in process, final products & piping projects in compliance with API, ASME & ISO standards.
• Successfully completed GRP piping projects (Cross-Country & Industrial) within time & budget allocated.
• Led & motivated the plant, marketing & project teams to achieve productivity and assigned targets.
• Achieved sales target and highest production of 1250 GRP pressure class pipes (0.8m.Dx12 m L) pm as National Record.
• Adapted and executed cross-country projects of 180/90/80cm dia pressure class pipes, first of its kind in sizes, in India.
Mar '01 - Jan '03 Shri PET Industries Ltd., Chennai General Manager
• Administered the operations of Plastic Process Machines for mass production of PET performs / bottles & jars through Injection Molding, Blow Molding & Multi Stage Molding processes with optimum utilization of resources including Contracts Management
• Conducted QA/QC of incoming materials, outsourced components/assemblies & products to optimize product quality.
• Planned & implemented preventive/predictive maintenance schedules of production machines for reliable output.
• Reduce engineering issues related to CNC machining, C turning, Optical Profile Grinding, Machine Centre, Honing, Boring and CNC Spark Erosion Processes.
• Instrumental in implementing TPM methods in manufacturing the machine tools/products.
• Optimized the higher market realization and the fund collection with minimal credit outstanding.
• Achieved 50% increase in productivity through effective PPC/process control & realized 10% saving of material resourcing.
Preceding Assignmen
Apr '99 - Mar '01 Sundram Fasteners Ltd., (TVS Group), Chennai Manager- U & SM
• Monitored the progress of Jushu Hozen / Kobetsu and Implemented TPM & Kaizen activates
• Contracts Development/ SCM and Installed and commissioned various industrial, mechanical & electrical systems; plumbing work, drainage, water & fire hydrant systems and construction of civil structures and roads.
• Executed the LPG Bullets Installation, Hot Nut Forging Module Expansion, Indigenization of production equipments and ETP modernization projects and efficiently reduced maintenance & fuel cost and utilities consumables.
• Increased machine up time and assisted the production department in improving production levels.
• Coordinated with Pollution Control Board, Inspectorate of Factories/Electrical Authority/Boilers Controller of Explosives and other regulatory bodies for securing approvals/certification & licensing.
• Conducted safety testing for Pressure Vessels/ Lifting Tackles/ LPG & HSD/ FO safety components and tanks.
• Resourcefully implemented preventive and predictive maintenance of electrical/mechanical systems and increased production by 10% with OEE 95% improved.
• Achieved +10% higher machine uptime by modified machine tool designs & reduced tool/job change hours.
• Revamped CNC, Forging/Hot Forging, Thread Rolling, Auto Electroplating as well as Phosphating equipments in a cost effective manner. Reduced maintenance/utilities cost by 20%/17%, fuel cost by 15%.
• Streamlined operations and information flow from functional areas using the MS Office and M S Project effectively.
May '97- Apr '99 Mahindra Construction Company Ltd., Chennai Construction Manager
• Contracts Management & executed projects of Hi-Rise buildings, resorts, institutions buildings & commercial complexes as planned
• Profitably executed civil construction work, interior decorations, roads and infrastructure (Power, WTP and WWTP & Disposal) projects comprising HT supply substations, Electrical Installations, HVAC, piping, plumbing drainage, etc.
• Instrumental in installing centralized HVAC units, Air Handling Units, Fire Hydrant System, ETP & WTP.
• Handled Club Mahindra Resorts projects at Munnar, India / Mahindra United World College of India at Pune, India.
Nov '93 - May '97 Aurofood Ltd., Auroville, Pondicherry Manager - Maintenance
• Spearheaded Production Planning functions as Coordinator & handled the Centralized Contracts/Projects & Maintenance Division.
• Supervised end-to-end execution of projects for civil/structural of factory buildings & expansion/renovations.
• Restructured the plants of Flour Mill, Biscuit Production, Pasta Extrusions and Cattle Feed Mills.
• Implemented civil, electrical, mechanical & utilities maintenance schedules of proactive and preventive maintenance.
• Efficiently reduced maintenance cost by 30%, fuel cost by 17% and utilities consumables by 24%.
• Indigenized several imported machines, reorganized the Flour Mill, Pasta Extruders, Feed Mill and Mixers.
• Significantly improved tonnage production by 23% for biscuits, 15% for pasta, 31% for wheat flour and 35 for cattle feeds
Jun '92 - Oct '93 Asian Paints (India) Ltd., Patancherru Senior Engineering Executive
• Executed various Contracts Management/SCM & EPC projects and headed the entire engineering functions.
• Provided assistance in the maintenance of plant machinery of: o Ball Mills, Hi-Speed Mixers/Dispensers, Attritors, Bead Mills, Emulsion/Enamel Mixers, Sand mills
o Ribbon Blender, Pug Mixer, Hyro Shakers, Jacked Vessels, Wall Filler Mixers, Thinner Mixers
o Sigma kneader, Twin shaft disperser, Reactors plants etc.
• Took preventive maintenance of utilities like: o DG Sets, Boilers, Thermopac Units, Condensers, Chilling Plants, Cooling Towers, Air Compressors, Clean Air supply units, WTP, ETP, etc.
• Managed projects of power/ water supply and implemented measures for resource optimization.
• Developed cost effective substitute for imported equipments of Pug Mill/Filter/Reactor/Coupling Systems/vacuum Pumps
• Managed the engineering stores & JIT and ensured inventory control for spares/consumables/utilities.
• Coordinated with shop floor and contributed +12% in production.
• Achieved 8% saving in cost through spares inventory.
• Reduced 6% production cost by implementing machine modification and design improvements.
• Indigenized Pug Mills, Filters, Reactors, coupling systems. vacuum pumps and reduced recurrence by Rs 2.6M pa.
• Successfully completed the Resin House Reactor Plant, IP-Units, Bazaar Paint units Upgrade & Clean Air Supply Plants.
• Undergone 3 months 'UNIDO' Fellowship Training in England arranged by UNDP and Govt. of India. Academia • B.E. (Mechanical) from Thiagarajar College of Engineering, Madurai Kamaraj University, Tamil Nadu, India in 1982. Permanent Address: 26/2102, Jivan Bhima Nagar, Anna Nagar West Extension, Chennai-600101 Contact Numbers: +91 9962874905/9789908028 (India) Passport Details: K4337208 expiring 05.03.23 Current location & Visa Details: Bahrain Work permit Number of Dependents: 2 (wife and son)