General Manager Technical
Power Chemical Industries
Total des années d'expérience :29 years, 11 Mois
Responsible to Explore New Products /Projects in the company's portfolio,
Responsible to relocate existing units (partial) to the new facility along with the new installation and commissioning all units safely to productions by planning & execution the units in phases without any delay & interruption,
Process Optimization of the existing facility to decrease process losses to minimum etc.,
• Providing Mechanical work Services (fabrication of tanks, equipment, plant erection, piping, steel structure work) on labor rates with or without materials or turnkey basis as per convenience of clients.
• Providing process Consultancy to the industrial sector by continuously adopting to Customer’s needs,
• Carrying out /providing services to execute annual turnaround /shut down activities to its clients observing highest level of HSE standards and safety gadgets.
As Plant Manager my key responsibilities are:
1. Managing operational & fiscal activities to include: staffing levels, budgets & financial goals,
2. Meeting cost efficient production targets,
3. Planning & developing system & procedures to improve the operating quality & efficiency,
4. Trouble shooting, Root cause failure Analysis & developing solutions to enhance reliability,
5. Writing SOP and safety procedures in accordance with HSE standards & company’s culture,
6. Study & Development of new Projects & Products,
7. Process Engineering Calculation like Heat & Mass Balance for yield factor &Energy allocations,
8. Training, Motivation & Performance Appraisal Evaluation keeping in view company’s policies & procedures,
9. Quality & Energy audits
10. Management Representative for ISO 9001:2008
• Providing Plant based Production and Engineering expertise, ensuring total support for Production activities of the plants meeting specified quality standards through CENTUM CS 3000 & YOKOGAWA XL DCS Systems simultaneously,
• Applying technical knowledge and Supervisions skills to obtain efficient operations and Troubleshooting the problems encountered at plant and device a plan to avoid its repetition in future,
• Managing the in time delivery of Production Targets by consuming standard raw material factors through cost effective and opined utilization of resources,
• Planning & coordination with other departments to foresee & overcome difficulties before they effect as well as Annual Turn around Activities of the complex in comply with Annual Production Plans,
• Preparation of monthly Production Forecast in accordance with Sales Forecast, and controlling the revenue expenses within budgeted figures,
• Formulation of the Annual, 3 years & 5 years Capital Expenditure Budgets including the detailed proposals & justifications for major investment /Fixed assets,
• Initiator for plant improvements, modifications, development and updating of SOPs and monitoring and measurement systems for all three plants ensuring the implementation of HSE policies and standard,
• Educating and training production employees on production, quality and safety procedures, Retention & motivation of talented & high potential individuals,
• Managing Production staff for smooth working in shifts maintaining high performance and their related administration affairs, and performance appraisals evaluations, by implementing continuous improvement process & culture,
• Preparing daily production reports, monthly closing /activity reports & yield calculations as well as material and energy balances to measure & analyze the Performance of the plants,
• Carrying out the Energy Audit of the plants and explore the possibilities of reduction in energy costs all the times.
• Monitoring the implementation of the organization’s HSE policy, and Reporting progress to the Company’s chief executive,
• Advising line management on the implementation of HSE policy, and assisting them in identifying unsafe working conditions and practices in all three facilities with unified approach,
• Assisting in designing SOP’s for both normal and emergency operating conditions,
• Recommending suitable protective clothing and equipment,
• Checking compliance with statutory requirement & informing line management on all new legislation, regulations and codes of practices,
• Identifying training need analysis and recommending the appropriate training programs for the employees to enhance HSE awareness,
• Monitoring the correct updating of registers and accident incident records,
• Assisting in the investigation of incidents /accidents to establish the cause and recommendations to prevent its reoccurrence,
• Developing accident prevention techniques by promulgating information on accident and incident reports,
• Providing meaningful incident /accident and performance-related statistics,
• Assessing the hazards associated with materials and equipment, and monitoring the exposure of personnel,
• Verifying the emergency response procedures, together with the unit’s state of readiness for the emergency,
• Monitoring the performance of contractors in observing the unit’s HSE policy and procedures,
• Carrying out safety inspections and annual safety audit of all items /equipment of Company’s facilities,
• Liaising with other units & external professional associations and regulatory authorities.
(In addition to HSE affairs)
• Carrying out the Energy Audit of the plants yearly and explore the possibilities of reduction in energy cost in close working with the respective users,
• Develop cost effective energy conservation measures and procedures & evaluate technologies and review plans for potential energy conservation opportunities.
. Managing and coordinating plant & utilities operation in safe and efficient way by Distributed Control System.
· Preparing strategies to ensure production specifications and loss minimization of resources & Suggesting modifications
for efficient and safe operation.
· Contributing to the preparation of standard operating procedures to ensure safe, hazard-free working and conducting
training plans/programs for the Trainee Engineers, Supervisors and Plant operators.
· Controlling the dispatch of finished products in tankers by an efficient loading system.
· Handling the unloading of raw-material tankers and maintaining the loading/unloading procedural documents.
· Contributing to the planning and scheduling of preventive & shutdown maintenance.
• Managing Plant operation in safe and efficient way.
• Attending process related problems coming across during shift and carrying out supervision of any electrical, instrumentation and mechanical breakdown jobs.
• Planning of preventive and shutdown maintenance.
• Suggesting modifications for efficient and safe operation and finding ways for reducing operating cost.
• Managing and monitoring start-up and shutdown activities, safety measures, work order issuing, coordination, logging, supervision of annual turn around activities.
Production of 10 ton perday of Citric Acid by Fermentation, A Feasibility survey report of Drying & Preservation of Fruits & Vegetables, Two month internship in RAFHAN MAIZE PRODUCTS LTD. Faisalabad