Balashanker Kesana
Toranangallu
Summary
Results-driven Manager with a strong work ethic and commitment to exceeding organizational goals. Proven ability to build productive relationships and foster team development in fast-paced, deadline-oriented settings. Skilled in leveraging theoretical and practical knowledge to drive initiatives and support organizational success.
Overview
10
10
years of professional experience
1
1
Certification
Work History
Manager
JSW Steel Ltd
Vijayanagar
03.2021 - Current
- Working as Area In charge Maintenance for Managed maintenance operations for Asia's largest Indurating Machine and associated equipment.
- Executed zero breakdown and zero maintenance strategies for critical equipment to enhance operational reliability.
- Awarded as the 'Best Employee PP3' for the FY25 for Online cleaning system Installation for Burners and Optimizing the furnace parameters for reducing the energy consumption by developing Python based Prediction model.
- Rated as an 'OUTSTANDING' in appraisal throughout the career from FY19.
- Created master data including FL, work center, equipment, task list, and maintenance plans for Pellet Plant 3 in SAP PM module.
- Addressed major issues in Indurating pallet cars, reducing annual replacements from 302 to 169 and planning for 127 cars in FY26.
- Reduced Specific Maintenance Cost by Rs 0.62/ton of Pellet (43 lakhs/annum).
- Reduced pellet conversion cost by improved productivity Rs 0.42/ton of Pellet (29.5 Lakhs/annum).
- Implemented Burner Strainer Online cleaning system for the TAR contamination which enhanced the Productivity from 900 TPH to 1250 TPH without any temperature profile drop.
- Implemented Online Spring seal bar cleaning and Rapping system to avoid jamming of Spring seal bars and air leakage or false air entry on the carrying side.
- Understood the root cause for the failure of down comer refractory and nullified the issue by enhancing the combustion air pressure so that flame can be propagated further and necessary interlocks introduced to avoid future failure of refractory due to local burning gases.
- Attended major failure of 50M2 suspended roof with modified plate and gunning arrangement which successfully ran from 4th April 2025 with No red hot spots or furnace leakages.
- Developed Prediction models for the Targeted Quality using the Previous History data taking chemistry and Furnace parameters as input.
- Eliminated the single Party procurement by developing alternate vendors for DDRS rollers by saving specific cost of Rs 1.85/ton of Pellet (1.29 cr/annum).
- Installed online header cleaning chutes for WBR, extending impeller hard facing life from 2 months to 4-5 months and minimizing manual cleaning effort during shutdowns.
- Modified the HLS screen matte Tear drop sizes for Improved hearth layer 10-20mm from 86% to 91-94%.
- Implementation of CLS systems for conveyors Mixed ore, Reject series and filtration series by covering up to 1000 points by FY26 planning to cover all the 116 conveyors about 5400 Points.
- Designed and implemented the Hydraulic lifting mechanism for GP3 conveyor to reduce the MTTR by 2 hrs.
- Designed & Implemented Online oil replacement system for DDRS.
Project Engineer
JSW Steel Ltd
Vijayanagar
02.2019 - 03.2021
- Acted as project engineer for Pellet Plant 3 projects, contributing to Asia's largest pellet plant in capacity and world's 6th largest plant.
- Erection, Installation & Commissioning of Asia's largest Indurating Machine with 296 Pallet cars.
- Erection and Commissioning of Ball Mill (120TPH) and Vertical Mill (20TPH) along with accessories like baghouses, Rotary air lock valves and its pneumatic conveying systems.
- Executed erection, installation, and commissioning of 36 burners and 804 m² furnace, enhancing overall plant functionality.
- Erection, Installation & Commissioning of 7 Process Fans (9MW - 2nos, 6MW - 2nos, 4MW- 2nos, 2MW - 1nos).
- Set up three bag filters with integrated fans and purging solenoid shutoff valves.
- Erection, Installation & Commissioning of Vibrofeeders 5nos of 1200TPH, vibrating screen of 750TPH with their corresponding conveyors and Double Deck Roller Screen containing 60 rollers which feeds to machine pallet car and two conveyors for reject.
- Erection, Installation & Commissioning of Reciprocating conveyor with its Hydraulic Power Pack Unit.
- Erection, Installation & Commissioning of centralized Dual line Lubrication of 215mtr long machine, Lubrication systems for Ball mill, Vertical Roller Mill & Process Fans.
- Collaborated as key member of cross-functional team, facilitating integrated trial runs of equipment including indurating machine, process fans, furnace, ball mill, and vertical roller mill across the plant.
Vocational Trainee
RINL Vizag Steel Plant
Vizag
05.2016 - 06.2016
- Assisted in operating machinery for steel production processes.
- Monitored equipment performance and reported issues to supervisors.
- Collaborated with team members to maintain workplace safety standards.
- Analyzed processes in medium merchant structural mill and resolved issues with reheating walking beam furnace.
Education
Emerging Leaders Programm - Organizational Leadership
XLRI Jamshedpur
Jamshedpur01-2026
MINI MBA -
IIM LUCKNOW
Lucknow04-2025
Data analytics and machine learning -
IIT Bombay
Mumbai04-2024
B Tech - Mechanical Engineering
National Institute of Technology
Karnataka05-2018
XII (B.I.E. AP) -
Narayana Junior College
Vijayawada05-2014
X -
NEWS School
Nalgonda05-2012
Skills
- Process Optimization
- Equipment analysis
- Failure analysis
- Failure analysis
- Kaizen implementation
- Automation Strategies
- Process automation
- High RPM equipment
- Alignment
- Failure analysis
- TQM implementation and Daily management of KPIs
Certification
•Emerging leaders Programm, XLRI Jamshedpur, Jan2026
• Mini MBA - JSW Young Leaders Program, IIM Lucknow, 05/24, 04/25, Typically understood and learnt a condensed version of core MBA subjects like business management, strategy, leadership, marketing, finance, and operations., Developed a centralized dashboard to reduce the Idle time for the earth and Heavy moving equipment in the Dolvi Jsw plant incorporating the user feedback on the driver and Vehicle booking with notification to improve the effective utilization., Won the First prize for Best project implementation and presentation.
• Data analytics and machine learning using python, IIT Bombay, 01/24, 04/24, Understood and Learnt to develop machine learning models and completed capstone project to predict the required operating parameters for the required strength in the CRM coils., Developed prediction models for CCS and Tumbler Index for Pellet plant 2 and Pellet plant 3., Developed a Prediction model for Optimized process operating parameters for different feed rate and given quality for Pellet plant 3.
• Mini MBA - JSW Young Leaders Program, IIM Lucknow, 05/24, 04/25, Typically understood and learnt a condensed version of core MBA subjects like business management, strategy, leadership, marketing, finance, and operations., Developed a centralized dashboard to reduce the Idle time for the earth and Heavy moving equipment in the Dolvi Jsw plant incorporating the user feedback on the driver and Vehicle booking with notification to improve the effective utilization., Won the First prize for Best project implementation and presentation.
• Data analytics and machine learning using python, IIT Bombay, 01/24, 04/24, Understood and Learnt to develop machine learning models and completed capstone project to predict the required operating parameters for the required strength in the CRM coils., Developed prediction models for CCS and Tumbler Index for Pellet plant 2 and Pellet plant 3., Developed a Prediction model for Optimized process operating parameters for different feed rate and given quality for Pellet plant 3.
Accomplishments
- Basic data analytics and prediction models using Python.
- Secured AIR 476 in the GATE Production Engineering 2022 examination.
- Secured a score of 648 in the GATE Mechanical Engineering 2018 examination.
- Secured a score of 674 in the GATE Mechanical Engineering 2019 examination.
- SAP PM usage and creation of master data.
- AutoCAD drawings viewing and editing.
- Team player, and also able to work independently.
- Ability to grasp concepts at a brisk pace.
- Willingness to learn and gain more knowledge.
- General arrangement drawing reading, and able to plan parts erection sequence and alignment.
Hobbies and Interests
- Playing Games like Badminton, Caroms, Chess and Cricket
- Interested in Planning and Organizing Events
- Have special interest in dancing and participated in many cultural events in school and college events
Projects
- Lattice Boltzmann Computation of Creeping Fluid Flow in Roll-Coating Applications, Isac Rajan, D Arumuga Perumal, ICDMM conference, Forwarded to AIP Conference proceedings
- Lattice Boltzmann Simulation of Double-Sided Deep Cavities at low Reynolds number, Vikas V Shetty, D A Perumal, Innovative Design, International conference on Analysis and Development Practices in Aerospace and Automotive Engineering (I-DAD 2018), 02/22-02/24/18, Veltech University, Chennai, Tamilnadu, Forwarded to Frontiers of Mechanical Engineering, Springer
- Patent: Analysis of Fluid Flows in Bounded Domain with Particular Shape of a Cavity using Lattice Boltzmann Method, Bentham Science Publishers, pp. 359-372(14), Shetty, Vikas V., Balashanker, Kesana, Dharmaraj, Arumuga Perumal, Patel, Vedant Umang
Languages
- English
- Hindi
- Telugu
- English
- Hindi
Timeline
Manager
JSW Steel Ltd
03.2021 - Current
Project Engineer
JSW Steel Ltd
02.2019 - 03.2021
Vocational Trainee
RINL Vizag Steel Plant
05.2016 - 06.2016
Emerging Leaders Programm - Organizational Leadership
XLRI Jamshedpur
MINI MBA -
IIM LUCKNOW
Data analytics and machine learning -
IIT Bombay
B Tech - Mechanical Engineering
National Institute of Technology
XII (B.I.E. AP) -
Narayana Junior College
X -
NEWS School