PANKAJ MISHRA

Experience

• 

  Hindalco Industries Limited

  Jul 1992 - Mar 2009

  Assistant General Manager - Reduction Maintenance

  Hindalco, Renukoot, India comprises an Alumina refinery, Reduction, and Fabrication Plants. Reduction consists of a Carbon Plant, 11 Pot lines, and Cast House & Billet Casting. I led a team of 55 senior staff, 350 technicians, and 120 contractors.Spearheaded initiatives aimed at enhancing operational effectiveness, generating increased revenue, and streamlining processes. Exhibited robust mechanical aptitude and process control knowledge, complemented by strong leadership ability in a plant management position in a heavy industry environment. Monitored and managed the operations & maintenance across multiple facilities (11 potlines) while ensuring adherence to HSE regulations.Managed operation & maintenance of a 2.4 km long alumina transfer system from Alumina Plant to Reduction Plants 1 and 2 and ensured its availability.Collaborated with contractors for pot relining activities and reduced pot turnaround time from 120 to 94 hours leading to enhanced production and improved energy efficiency.Ensured preparation, and implementation of Capex / Improvement projects to improve efficiency, productivity, and HSE conditions & to reduce cost, and energy consumption norms.Led the team to develop an in-house Automatic Alumina Feeding System reducing Alumina consumption by 0.2 MT/ MT of Al production reducing resource wastage, controlling dust pollution contributing to sustainability goals.Represented Plant operations and coordinated the installation & commissioning of Brownfield fume Treatment Plants for Potlines 1, 2, 3, 5, and 6, valued at 11M USD.Represented Plant operations and coordinated for the Brownfield Capacity Expansion Projects encompassing Potlines 7, 8, 9, 10, and 11. It doubled the liquid aluminum capacity.Managed long-term maintenance planning & procurement of spares, capital equipment, & contract services.Dealt with contractors & vendors for project material procurement, service contracts, installation, commissioning & startup of equipment. Show less

• 

  Qatalum

  Apr 2009 - Sept 2020

  Orchestrated the asset management strategy by providing leadership & strategic direction based on the industry’s best practices.Developed new vendor, used alternative materials & other cost reduction activities to lower the maintenance cost.Championed Cost Improvement initiatives under BLITZ Kaizen initiative for maintenance material & contract services, achieving savings exceeding 3 MUS$/ year on a sustainable basis.Fixed Store Stock level, re-ordering levels for materials, identified non-moving items & initiated actions to dispose of such material. It also helped the Warehouse to dispose of unwanted items and created space for proper storage of required items.Enhanced machine availability through the optimization of the preventive maintenance cycle especially Pot Tending Machines from 8 to 16 weeks. It reduced the required staffing and released substantial amounts of engaged resources for other operational activities.Anticipated and countered the causes and the failure modes that degraded equipment performance earlier than expected.Identified & implemented predictive and corrective actions based upon RCA to prevent the re-occurrence of failures.Monitored the critical asset performance of the entire facility and initiated long-term & short-term plans based on the analysis.Ensured RCM and FMEA performed & escalated issues and risks to allow adequate investigation and subsequent resolution.Spearheaded safety initiatives, conducting critical incident investigations and implementing corrective actions to prevent recurrence.Collaborated with various departments to ensure the alignment of operational objectives and business goals. Show less Qatalum Reduction Plant has 704 Pot cells, arranged in 2 potlines, 4 Fume Treatment Plants with Material Distribution Systems, a Laboratory, Cathode Rodding, and a Crucible Cleaning shop. Led a team of Supervisors, a Planner, and Technicians with contractors. Full-scale systematic project and maintenance management within established procedures, plans, budgets, and timelines. Significant AchievementsRepresented Plant operations and coordinated the successful erection, and commissioning of the 5.6 BUSD Qatalum Greenfield Smelter Project with various project disciplines and vendors. P&ID, FMEA, HAZOP, Handling of punch items, follow-up for milestone targets ensuring closure on punch items, guarantee notifications, review and comment on takeover dossier, Site WOC, Management reporting on progress & co-ordination with Hydro Projects to address punch items and ensure on-time closure for warranty claims towards SNC Lavaline, five Solios France and FATA as EPC Contractors and main subcontractors like ABB, Claudius Peter, Germany, Rio Tinto Alesa, Switzerland and NKM Noell, Germany.Devised and monitored a comprehensive maintenance strategy encompassing all equipment's preventive & corrective maintenance actions and supported the planning & scheduling function.Ensured effective maintenance of various electrical, mechanical & hydraulic equipment within the Plant.Development of SOPs, OPLs, Work Instructions, and procedures in alignment with business objectives & continuous improvement.Contingency Planning – Hazard Identification, Risk Assessment, and Risk Mitigation PlanRecruitment, training, and competence development of the team.Conducted pot relining activities for early failed pot cells.Received CEO Improvement award for reducing the cost of operational consumablesCollaborated with procurement to acquire necessary materials and services for smooth Plant operation.Ensured implementation of identified Improvement proposal within the approved budget. Show less

  • Senior Reliability Engineer

    May 2016 - Sept 2020

  • Pot Line Maintenance Superintendent

    Apr 2009 - Apr 2016
• 

  Suhail Industrial Holding Group, Qatar

  Sept 2020 - now

  Senior Mechanical Engineer

  Formulated and implemented robust maintenance strategy and organization for all the equipment and facilities of the Suhail Industrial Holding group companies. It covers factories recycling Aluminum, Copper, Iron, and Batteries and producing various Plastic products, Scaffolding, Batteries, Brake pads, Bronze, Cast Iron, Geotextile, and metal forming /engineering facilities.Administer maintenance of diverse equipment, including Induction furnaces, casting lines, EOT cranes, Injection molding machines, pumps, compressors, rotating machines, Crushing, Screening, Material conveying, and CNC fabrication machines.Coordinated project activities related to the erection and commissioning of various equipment for Group factories.Ensured identification, procurement, and storage of spare parts & arrange services for the plant operations.Foster a safety culture by promoting risk management, safety interactions, and developing preventive strategies.Supervised construction, commissioning, and operational readiness for diverse manufacturing units.Ensured compliance with standards and best practices in equipment selection and installationCollaborate with cross-functional teams to drive continuous improvements in operational efficiency, reliability, and cost savings. Show less