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15/12 Mr.Ravikiran Reddy
Principal Consultant at Talent Source

Views:333 Applications:36 Rec. Actions:Recruiter Actions:8

Plant Head - Chemical (15-20 yrs)

MP/Indore Job Code: 30025

Job Description :

- Evolved strategies for implementing world-class maintenance processes to curb machine breakdowns, reduce the rejection rate, realize operational efficiencies, control variability, costs as well as reduce the cycle-time; managing a team and guiding staff members to address and resolve performance bottlenecks

- Leadership Experience in Operations & Maintenance of Sodium Sulphate Recovery System

- Should have Experienced in Operations of Viscose, Auxiliary, or Acid H2SO4 Plant.

- Managing Plant with minimum breakdown by Implementing systems like 5S, KAIZEN, FMEA, and WHY-WHY Analysis

- Should have experience of basic conceptualization to Commissioning in VSF Green Field Project, Sodium sulfate Recovery plant.

- Expertise in driving the projects to completion which aim to either minimize loss of material/energy in-process steps or to simplify the process (LEAN approach)

- Exhibited a firm approach to sustain and encourage safe work environments and capabilities to streamline operations; applied continuous improvement principles to increase process & maintenance efficiency and company profits

- Should be Strategic Planner : Developed, initiated, and evaluated new policies, procedures & internal controls; assessed & resolved complex operational problems; resourceful in ensuring sufficient human, financial, and technological resources are available to carry these out

Competencies :

- Plant Operations, Operations & Maintenance, Installation & Commissioning, Basic/Detailed Engineering, Quality Management, Operational Excellence, Budgeting & Forecasting, Vendor Management

Key Working Areas :

- Plan & Achieve sodium sulfate salt production & Its Quality.

- Spearheading entire gamut of operations entailing Production Planning & Process Calculations

- Implementing safety standards through RISK & HAZOP analysis

- Performing design vetting of various equipment with the vendor

- Supervising the selection of equipment based on TBA and meeting with various Foreign and Indian vendors

Highlights :

- Attained cost savings by reduction in raw material, steam & power consumption

- Drove out waste/non value added throughout the Lean Manufacturing

- Implemented ISO 9001-2000, EMS-14000, OHSAS 18001, SA8000 and IMS Systems

- Introduced &implemented SAP PP Module

- Commissioned equipment such as Multistage Flash Evaporator, Anhydrous Evaporator, Acid Absorption Crystallizer, and Salt Bagging & Packing System

Major Equipment Exposure :

- Multi-stage flash Evaporator, Anhydrous Triple effect Evaporator, Rotary Vacuum Filters

- Acid Absorption Crystallizer, Steam base Crystallizer, Rotary Drum Dryer

- Steam Ejectors & Vacuum pump, shell & tube heat exchangers, BHE & PHE

- Furnace, Absorbers, Converter, Reactor, Scrubber.

- Candle Filters, Sand Filters, Filter Press.

- Belt conveyors, Bagging and Packing Systems

- Cooling Towers& Refrigeration System.

- Production Planning & Control

- Determine production requirements based on plant capacity and production specifications.

- Plan workflow and schedules for production departments.

- Monitor production status and ensure timely delivery.

- Assist in production risk assessment and mitigation activities.

- Ensure that finished products meet quality standards and customer specifications

- Resolve production issues and escalate unresolved issues to management promptly.

- Monitor and analyze Downtime with Root cause to reduce its impact on Cost, Quality, and Delivery.

- Engaging with internal stakeholders for the smooth operation of the department.

Safety & Environment :

- Developing SOPs, JSA, HAZOP & SMP and periodic review for its up-gradation

- Lead/Support/Develop business-specific standards/best practices and efforts as directed by Business and Corporate.

- Assist plants in leading Process Hazards Analysis (PHA) for major risk projects by providing expert PHA methodologies.

- Support PSM Excellence implementation. Identify needs required to comply with PSM requirements.

- Assist the plants in their procedure development and provide direct support to their implementation efforts of new and existing standards and local process safety requirements

- Participate in Process Safety Event investigations/root cause analysis to guide to all plants. In conjunction with site management teams, track corrective actions where business-wide issues are identified.

- Evaluate events and operational results and support the revising / updating of site policies, procedure revisions, and training to address process safety-related findings.

Change management :

- Lead Continuous improvement culture among team members to deliver excellence in operations.

- Ensure Indian MNC Operational excellence guidelines are adhered to by continuous training, implemented, and reviewed using the RADAR framework of Indian MNC

- Knowledge transfer initiatives among inter and intra unit members to continuously improve the processes and systems

- Identify opportunities for joint improvement projects among departments, vendors, and suppliers through CFTs taking the lead on transition management, ensuring continuity of operations

- Assist in new product development and enhancements.

Project :

- Own the CAPEX projects to improve quality, cost, productivity within timelines resulting in significant business improvement and customer satisfaction.

- Ensure Onsite and offsite quality inspection of incoming materials to ensure the standards are met for quality parameters

- Ensure completion of process improvement projects within a specified time frame while achieving a cost reduction goal.

- Provide management with project status updates, feedback, and appropriate reporting on key responsibilities and objectives.

Regulatory compliance :

- Ensure all the relevant regulatory compliance applicable to the operations are adhered to.

- Participate in periodic regulatory compliance audits from external and internal parties to continuously improve systems.

Maintenance :

- Coordinate with maintenance teams to ensure maximum equipment availability for operations.

- Ensure implementation of QMS, EMS, OHSMS, and Operational Excellence guidelines for continuous improvement and maintaining standards.

- Coordinate and timely execution and commissioning of new development initiatives for improvements

Planning & budgeting :

- Propose the department P&B in the area of Consumption ratios, Maintenance cost, resources management, etc., to management for approvals and achieve the same by deploying resources.

Customer eccentricity :

- Continuously create awareness about customer-eccentricity among team members to build a customer-oriented mindset.

- Managing customer complaints in consultation with CTS.

- Ensure Quantity & quality parameters of the products/services supplied to internal and external customers

- Provide excellent customer service and ensure customer satisfaction.

People Management :

- Ensure employees are aware of their roles and responsibilities and deliverables

- Create an enabling environment to discuss and share people issues at the workplace

- Identify and facilitate appropriate training of competency gaps with the help of the HR department

- Encourage and model the recognition culture at the workplace

- Ensure Safety and Environment awareness among employees and training wherever required

- Develop line managers into people managers to handle day to day grievances with the utmost sensitivity

Regulatory compliance :

- Ensure all the relevant regulatory compliance applicable to the operations are adhered to

- Participate in periodic regulatory compliance audits from external and internal parties to continuously improve system

Maintenance :

- Coordinate with the maintenance in periodic maintenance and troubleshooting to ensure availability and reliability of equipment.

- Coordinate and timely execution and commissioning of new development initiatives for improvements

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