Production Incharge
Energya Plastics
Total years of experience :9 years, 4 Months
• Carry out plant operations so as to ensure the extrusion compounding of electrical cable grade PVC, MVXLPE (Medium voltage cross-link low-density Polyethylene), LVXLPE (Low voltage cross-link low-density Polyethylene), HFFR (Halogen free flame retardant) compounds.
• Cross-functional liaison with sales /QC and engineering to ensure machine availability and on-time delivery of standard products as per customer requirements.
• Works with a sense of urgency that enables production schedules to be met while minimizing unnecessary costs related to downtime and labor and material variances, without jeopardizing the health and safety of the general workforce and/or the quality and accuracy of production and without violating established work standards and ISO requirements.
• To maintain the daily routine maintenance of the plant to minimize the breakdowns and loss of production.
• Worked on the ERP software i:e Epicor an American system modulator specifically for raw material consumption, supply chain, inventory, distribution, manufacturing production, and cost control.
• Supervise and monitor the daily production from raw material to the finished product.
• To verify all process control parameter is being documented as per the ISO standards and followed as per the required SOP.
• Involve in commissioning and erection of machines, training, and development of staff, conducting time studies, and setting standards.
• Conducting process trials for new materials and products, with the coordination of relevant departments and preparing a comprehensive process trial report.
• Handle plant emergencies and operational upsets in a way to ensure the safety of personnel, environment, equipment and minimize production loss.
• Involved in the operation, inspection, and troubleshooting of process plant utilities of static, non-static, and analytical instrumentation.
• Issuance of work permits, lead, plan, coordinate and ensure that all HSEQ (Health, Safety, Environment & Quality) procedures of the company and local regulations are complied with during operations, maintenance, and annual turnaround at the plant.
• Control unit upsets and brings them to a safe and normal operation level.
• Communicate with unit licensors & vendors for process improvements and new technology.
• Have the ability for technical bid evaluations. Reviews vendor documentation and comments to ensure design conformance.
• Handles very efficiently the total DCS (Distributed control system) and other advanced technology systems installed in the plant to monitor and control the unit operations.
• Works as a liaison, if nominated between operations and other organizations when a mechanical modification or additions are being made to the unit under control.
• Perform troubleshooting and problem-solving during equipment or unit failure and performs start-up and shutdown of the equipment/unit safely.
• Operates the distillation columns closer to fractionation targets. Achieves faster recovery to stable operation after upsets, smooth transition during changes to new targets, and reduces product giveaways.
• Procurement support, vendor document review, and ensuring appropriate financial planning to maintain the financial system and achieve financial targets.
• Provide technical guidelines and motivation by developing and supervising proper training plans for operators and subordinates at the unit and also in the classroom to improve their performance.
Projects overview:
•Erection of 5-ton Fixed plate HEX.
•Placement of 20-ton of activated carbon in adsorber, and replacement of its PTFE mesh.
• Placement of boiler refractory.
• Placement of molecular sieves of dehydration unit.
• Reduction of water content from Alcoholic products.
• Calibrating the PSV, PCV, and analytical instrumentations on the plant.
• Expert in plastics research, development, testing, analysis and processing.
• Responsible for developing design concepts of polymer materials and provide necessary recommendations to improve product specifications, if required.
• Proficient in running processing machines like extrusion and injection molding and also trouble shoot any problem with them.
• Formulation of PVC pipes on local scale to reduce the cost of raw material.
• Handle the tasks of developing processes and new applications for manufactured polymer products.
• Execute mechanical testing of plastic samples by ASTM and ISO standards. Assigned responsibilities of supporting development teams towards product improvement and application feasibility.
• Performed environmental tests such as creep, high temperature thermal aging, high pressure/high temperature fluid aging, and chemical aging on the samples.
• Perform the tasks of managing projects and analyzing root cause failures in the developed products.
• Played as a billable resource in process development project.
• Handled responsibilities of writing the fundamental characteristics polymer and product development procedures.
• Experienced with QA/QC testing and test data recording and maintenance for Quality Compliance.
• Responsible for preparing drawings, determining feasibility of design, and reviewing product manuals.
• Ensure that the manufactured and delivered product meets quality standards and guidelines.
• Assigned the tasks of assisting senior level engineers in performing failure investigation and root cause analysis of failures.
• Write monthly reports and also technical reports for projects to use for business development.
Activities and Societies: Member of AiChE (American institute of chemical engineering). Cost estimation of chemical plant and pilot scale project for the calculation of costs of different installed equipment’s on a plant.
Physics, Chemistry, Mathematics
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