Experience

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  Khyber ind. pvt. ltd

  Jul 2005 - Mar 2007

  Process manager

  Started my journey in pre-commissioning phase of this plant was a real booster for my whole career. I have high gratitude particularly for Khyber Industries to impart unstoppable inertia to my career in cement industry. Started my regular job as a CCR Operator in 2005 and departed from this company as a process manager in 2007 was one of the great journey of my career in cement industry. I was appreciated for demonstrating excellence in implementing operational efficiencies in the process and accomplishing quality benchmarks by adopting state of the art production techniques and tools of management.Thanks Khyber industries Pvt. Ltd! Show less

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  Flsmidth

  Apr 2007 - Jun 2010

  Lead commissioning engineer.

  At FLSmidth my job portfolio included following activities in cement industry sector.Performing of pre-commissioning activities, like equipment readiness check, trial run, operational and safety/protection interlocks as per standard pre-commissioning protocols. Commissioning activities, like no-load run, cold commissioning, hot commissioning of all equipments.Attending and attempting various operational problems encountered during commissioning phase of project.Implemented standard operating procedures in operation and maintenance.Conducting onsite training for CCR operators and field staff training regarding the subject of personnel and equipment safety, plant operation and optimization.Maintaining plant operation at promised level and obtaining performance guarantees from customers at the completion of project.I had contributed in the following cement projects at FLSmidth.Commissioning of Pena Cement (Thadipatri, A.P); 3800 TPD.Trouble shooting (In Cooler & FRF-Silo) of Vasavadatta Cement Line III, Karnataka.Commissioning of Vasavadatta Cement Line IV (4200 TPD), KT, also acquired PG for the plant.Commissioning and Plant Optimization of Priya Cement industry (Kurnool, A.P).I received appreciation from the management for demonstrating excellence at work for implementing operational and process improvement through effective cost reduction, tactical planning and productivity gains. Show less

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  Trumboo cement industries private limited

  Jun 2010 - Jun 2016

  Production manager

  Successfully administered complete functioning of Production and Quality Department activities.Maintained smooth cement industry operation with minimum down time and production cost.Generating and analyzing plant production and quality reports with the objective to identify optimization opportunity for overall improvement.Developing time schedule for maintenance programs and estimating time required for the job. Spearheaded complete Plant Operations including trouble shooting & safety management.Ensuring the optimum and safe operation of crushers, Ball Mills, Kiln and Inertization unit from CCR.Formulating production plans and schedule, developing financial projections, preparing budgets and performing extensive costing for ensuring optimal utilization of resources and achievement of predetermined targets. My responsibility also included steering preventive and predictive maintenance schedules, identifying and resolving bottlenecks through application of trouble shooting tools. I am also responsible for maintaining the audit documents, coordinating and supervising the activities of Production department, Engineering Department, Quality & Process Control Department, and Safety Section for maintaining overall production efficiency. Benchmarking and process audit for heading optimization campaign to improve overall productivity and reliabilityImplementation of energy saving projects and ensuring adherence towards the safety compliance and regulations in the plant. Achieved successfully production targets by efficiently managing the engineering stores, which resulted in optimum utilization of resources at minimum inventory costs and achieved the operational efficiencies by proactively resolving the machinery breakdown issues using various trouble shooting tools and ensured the effective functioning of preventive maintenance work by using various troubleshooting tools. Show less

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  Qassim cement company

  Jun 2016 - Jun 2017

  Process engineering specialist

  Development of strategical planing for process analysis and performance review of three plants with a total capacity of 10000 tons per day.Identification of optimization opportunity through preliminary and detailed process audit of each plant.Operational efficiency analysis through mass and heat balancing, grinding circuit analysis, separator efficiency analysis-tromp curve and particle size distribution.Production planning and review of daily production-quality and energy consumption reports.Maintenance planning and consumables review, like refractory management, grinding media management etc. Show less

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  Cement plant optimization @ cementindusneed

  Aug 2017 - now

  Cement industry process optimization expert

  Cement industry process optimization expert working on predictive control system and data analytics [SEEQ] integration in process information management system PlantWiki for Lean Automation, UAE.SERVICES AS TRAINERTraining, coaching and mentoring of operational and managerial staff to improve on plant operation with optimization.Training of fresh requirements to understand cement manufacturing process, CCR Operation, field supervision, safety concerns and adopt standard operation procedure right from the beginning.Training of process engineers and production staff to use correctly portable process instruments, like anemometer, thermocouple, RTD, radiation pyrometer, gas analyzer to take process measurements to establish heat balance, mass balance, and conduct detailed process audit of raw mills, kiln section, and cement mills.Hosting 9 Online training courses for cement industry professionals and 2 tailored corporate training courses for big cement industries; https://training.cementindusneed.com/SERVICES AS PROCESS CONSULTANTEstablishment of base line performance (KPIs) and performance gap analysis.Analysis plant reports. Suggestions and recommendations.CCR operation monitoring (on-site, off-line and online), analysis of deviations from standard operating procedures.Study of potential improvement opportunities in Production., Energy saving, Product quality,general Safety.Identification of potential expansion/modification projects to augment bottom-line.Measurement System Analysis(MSA) and Energy Audit* (Yearly)Inspection of major equipments in scheduled maintenance, suggestions and recommendations to improve processes.Contribution to facilitate inputs for establishment of Strategical, tactical and operational planning. Show less

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  Thyssenkrupp

  Sept 2017 - Apr 2018

  Commissioning manager

  Responsibility as Commissioning Manager for project coal mill 2 at cement industry named Misr Beni Suef Cement MBCC at in Egypt.Performed pre-commissioning activities, like equipment readiness check, trial run, operational and safety/protection interlocks as per standard pre-commissioning protocols. Accomplished coal mill 2 commissioning activities, like no-load run, cold commissioning, hot commissioning of all equipments supplied by thyssenkrupp France.Solved various operational problems encountered during commissioning phase of project.Implemented standard operating procedures for coal mill operation from CCR.Conducted onsite training for CCR operators and field staff training regarding the subject of personnel and equipment safety, plant operation and optimization.Special fire safety issues like spontaneous ignition of fine coal in kiln and calciner coal bins and the incidents of explosion in bag filters were thoroughly discussed with plant operation management team to enforce safety interlocks. Auto control of inertization with condensed CO2 injection in coal mill circuit and fine coal bins were recommended strongly.Performance guarantees met at site and PG certificate obtained from customer MBCC on behalf of thyssenkrupp industrial solutions France. Show less