Hi, I’m
Chennakesava Reddy
Jamul, Bhilai, Dist -Durg, Chhattishgarh
Summary
Committed and professional Maintenance and Projects Leader with 22 years of demonstrated success in Manufacturing Maintenance, Commissioning and Installation, Projects Execution, Projects Management, Team Management. Proven engineering prowess to analyze and identify equipment downtime, conceptualize, and implement solutions to improve availability through cost-effective maintenance methods. Exceptional mentor and coach; combine technical acumen with innate leadership abilities to train and manage top-performing teams
Overview
22
years of professional experience
Work History
ACC Limited, Jamul Cement Works Bhilai
Head Maintenance (General Manager Maintenance) )
08.2022 - Current
Job overview
- Provide Strategic and Technical Leadership to a team of 45 managers & engineers and 200 workmen in the maintenance department (Mechanical, Electrical & Instrumentation, Civil and HEMM) for a plant 9000 TPD clinkering line with 2.8 MTPA cement production.
- Prepare maintenance Budgets and monitor and reduce Costs through improved practices.
- Ensure that all equipment are in good working condition and minimize unplanned downtime. Work with plant team for development projects to improve safety, throughput, quality, and cost- effectiveness.
- Planned, Led and executed Capex projects worth INR 620 million, including Solid AFR system worth INR 20 million (in progress) & modification of RP re-circulation elevators to enhance higher output worth INR 70 million etc…
- Reduced overall inventory value from INR 450 million to INR 310 million (31.1% decrease) by analyzing equipment Lead Times, Turnover Rates, Failure Modes and Effects and accordingly optimizing inventory budgets
- Ensured 100% compliance of all equipment to Holcim Maintenance Methodology to optimize expenses, thereby reducing maintenance budget by 15%.
- Increased equipment uptime by establishing and employing Preventive Maintenance schedules for Crusher, Raw Mill, Kiln and Cement Mill assemblies; achieved Net Availability Index exceeding 90%, Kiln MTBF higher than 1000 Hrs and Mills MTBF above 225 Hrs
- The main equipment’s L&T supplied APCM 2030 Limestone crusher, KHD supplied Roller Press RPS220/180 for Raw mill, KHD supplied 5.6 X 82 mtr Kiln, IKN supplied clinker cooler 6.75 X 30 M and Loesche supplied LM 56.3+3 Cement Mill.
ACC Limited, Chanda Cement Works Chandrapur
Head Mechanical (Dy.General Manager Mechanical)
08.2017 - 08.2022
Job overview
- Provide Strategic and Technical Leadership to a team of 40 managers,engineers and SFAs in the Mechanical department for a 7000 TPD clinkering and 2.2 millon ton cement plant to maintain equipment's of L& T make APPM 2022 Limestone crusher, Pfeiffer make MPS 5600 B Raw Mill, FLS make Atox-30 Coal Mill, FLS supplied 5.5X86 mtr. Kiln and Loesche LM56.3+3 Cement Mill.
Develop and sustain Maintenance system for plant reliability NAI >90% including annual shutdown. - Prepare maintenance Budgets and monitor and reduce Costs through improved practices.
- Work with lowest cost per ton of cements in terms of stores & spares / Repair & Maintenance
- Work with Min manpower resources & best in bench-marking with cement industries.
- Responsible for implementing of Contractor Safety Management.
- Ensure that all equipment are in good working condition and minimize unplanned downtime.
- Work with plant team for development projects to improve safety, throughput, quality, and cost-effectiveness.
ACC Limited,Chanda Cement WorksChandrapur
Head Preventive Maintenance(Chief Manager Mech)
07.2011 - 08.2017
Job overview
- Provide Strategic and Technical Leadership to a team of 22 managers,engineers and SFAs in the Preventive maintenance department to improve the reliability of equipment through condition based maintenance and total lubrication management including planning of resources and material for complete plant.
- Implementation of HOLCIM Maintenance management system (MAC)
- Implementation of Condition Based Monitoring (CBM) system in plant like Walk By Inspection (WBI), Vibration analysis, Hot Kiln Alignment and Kiln measurements, Various key PMRs (Running and stop)
- Resource planning of maintenance activities.
- Conducting of weekly maintenance meeting to review overall maintenance system.
- Budgeting and Cost management to run the plant with optimum maintenance cost.
- Identifying bottlenecks areas and taking steps to rectify it by applying troubleshooting tools like Pareto,Root cause analysis (SOLVE) and FMEA.
- Preparing & floating of tenders to contractors, evaluation of offers, techno-commercial discussion & finalization of contract.
- Major shutdown planning for both Kiln and Cement mill circuits.
- Preparation of master data and Implementation of SAP PM and MM module for new Chanda plant.
ACC Limited,Chanda Cement WorksChandrapur
Section Incharge - Mechanical (Manager Mech)
10.2006 - 07.2011
Job overview
- Lead mechanical maintenance in the Cement mill and Raw Mill Section. Ensure equipment availability for production and reduce downtime through preventive maintenance practices.
- Ensured continuous availability of 150+ equipment by establishing effective Preventive Maintenance Schedules
- Analyzed equipment downtime through root cause analyses, machine reliability studies, and took corrective actions to reduce overall costs and breakdowns, pushed Net Availability Index above 90% and mill MTBF greater than 225 Hrs.
- Delivered certification of ISO 9001: 2008, 14001, 18001 for all processes in maintenance operations by leading standardization efforts and ensuring compliance.
- Coached more than 10 persons/month on standards and safety practices to ensure safe and efficient operations.
Rajashree Cement(Ultratech)Malkhed
Engineer, Mechanical Maintenance
07.2005 - 10.2006
Job overview
- Responsible for complete mechanical maintenance of all 3 units coal mill circuits - 2 Loesche supplied VRMs (LM26.3) and Ball mils.
Sanghi Cement LimitedKutch
Assistant Engineer - Mechanical Maintenance
02.2002 - 07.2005
Job overview
- During this period I worked in different sections of cement plant - Raw material handling, Raw Mill, Coal Mill, Kiln and Cooler and familiar with Loesche supplied VRMs- LM 26.3 & LM 56.3 and FLS supplied Stacker, Reclaimer, Kiln and Cooler, Bag house.
- Experience in maintenance activities of Loesche VRM like grinding roller overhauling, maintenance of Grate cooler, stacker, and reclaimer etc….
Education
RGM College,JNT UniversityNandyal,Andhra Pradesh,India
Bachelor of Technology from Mechanical Engineering
07.2001
By HolcimMumbai, India
HARP Certification
2015
By HolcimHolderbank
Preventive Maintenance Engineer Certification
2013
By SKF IndiaPune, India
Vibration Analysis Level -1 Training Programme
2011
By HolcimWadi
Transport And Dedusting Training Program
2003
Skills
- Manufacturing Maintenance
- Projects Management
- Preventive Maintenance
- Budget & Cost Management
- Installation and Commissioning
- Safety Compliance,Risk Analysis & Mitigation
- Staff Performance,Development and Training
- Resource Allocation
- HSSE
- Team Management and Co-ordination
- MIS & Evaluation
Accomplishments
- Executed part of Hot commissioning of ACC Chanda plant (Capacity 2.2 MTPA, 7000 TPD clinkering line) and ramped up in Year 2010 to successfully achieved Overall Equipment Efficiency of 90%.
- Executed part of new installation of world class TLM and Centralized Tool Room at ACC Chanda Plant in Year 2012.
- Bagged # 4 Rank in 2013 in Holcim World through superior maintenance practices; award is based on Holcim Radar Index, incorporating factors like HSSE, Production, Efficiency, Power, Cost etc.
- Selected for and earned Holcim Preventive Maintenance Engineer Certification with entailing one month training at Singettal plant, Switzerland.
Additional Information
- COMPUTER SKILLS | MS Project ● MS Office ● Advanced Excel● Auto CAD
Languages
English
Telugu
Hindi
Availability
See my work availability
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Timeline
Head Maintenance (General Manager Maintenance) )
ACC Limited, Jamul Cement Works
08.2022 - Current
Head Mechanical (Dy.General Manager Mechanical)
ACC Limited, Chanda Cement Works
08.2017 - 08.2022
Head Preventive Maintenance(Chief Manager Mech)
ACC Limited,Chanda Cement Works
07.2011 - 08.2017
Section Incharge - Mechanical (Manager Mech)
ACC Limited,Chanda Cement Works
10.2006 - 07.2011
Engineer, Mechanical Maintenance
Rajashree Cement(Ultratech)
07.2005 - 10.2006
Assistant Engineer - Mechanical Maintenance
Sanghi Cement Limited
02.2002 - 07.2005
RGM College,JNT University
Bachelor of Technology from Mechanical Engineering
By Holcim
HARP Certification
By Holcim
Preventive Maintenance Engineer Certification
By SKF India
Vibration Analysis Level -1 Training Programme
By Holcim
Transport And Dedusting Training Program
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