Summary
Overview
Work History
Education
Skills
Specialized Achievements
Timeline
GeneralManager
Malay Kumar Mallick

Malay Kumar Mallick

General Manager
DURGAPUR, W.B.

Summary

Distinguished and results-driven leader with over three decades of progressive experience, excelling in the power and steel industry. Proven track record of elevating operational efficiency and minimizing downtime through strategic planning, budget management, and innovative solutions. Expertise spans the commissioning of large-scale power plants, comprehensive maintenance oversight, and seamless integration of procurement strategies. Renowned for optimizing spares planning, negotiating cost-effective contracts, and implementing inventory control measures. A visionary with a keen ability to align organizational goals with dynamic industry trends, fostering cross-functional collaboration and achieving remarkable results in cost reduction and operational excellence. Now seeking to leverage extensive skills and achievements as a dynamic contributor to an innovative and forward-thinking organization.

Overview

37
37
years of professional experience
4
4
years of post-secondary education

Work History

General Manager

Steel Authority Of India Limited (SAIL)
Durgapur
07.2018 - Current
  • Promoted to General Manager and Serving as the maintenance and operations in charge of turbines and boilers and heading the Complete Power Plant Sector of SAIL DSP.
  • Managing seven boilers with a capacity of 68T/Hr each, five turbo blowers supplying air to the blast furnace with a capacity of 1,65,000 Nm3/Hr at a pressure of 2.0 Kg/cm2, and four turbo alternators, each with a capacity of 5 megawatts.
  • Had weekly sync ups with the Managing Director , regarding the Power Plant Sector Reports.
  • Introduced new methods, practices, and systems to reduce turnaround time.
  • Managed budget implementations, employee reviews, training, schedules, and contract negotiations.
  • Presented Ideas to CEO regarding more efficient techniques and increasing productivity.
  • Developed and implemented strategic financial plans, aligning with organizational goals and objectives.
  • Achieved tangible results in cost reduction, improved maintenance efficiency, and minimized downtime through effective planning initiatives.
  • Continuously evaluated and adjusted planning strategies to align with dynamic organizational needs and industry best practices.

Deputy General Manager

Steel Authority Of India Limited (SAIL)
Durgapur
08.2013 - 06.2018
  • In August '13, transferred to SAIL, ISP, Burnpur, W.B for the commissioning of a 4640 m3 Blast Furnace.
  • Participated in planning process to achieve the deadlines
  • Successfully oversaw the commissioning process.
  • Maximized operational excellence mentoring personnel on management principles, industry practices, and company procedures.
  • Reviewed performance results to target and take corrective measures with authorization and escalation.
  • Orchestrated meticulous spares planning, identifying critical components for maintenance and minimizing downtime.
  • Implemented streamlined procurement processes, negotiating favorable contracts to optimize costs without compromising quality.
  • Implemented performance metrics for spares utilization, procurement efficiency, and inventory turnover, enabling continuous improvement.

Assistant General Manager

Steel Authority Of India Limited (SAIL)
Rourkela
06.2008 - 07.2013
  • Promoted and transferred to SAIL Rourkela Steel Plant in August '12.
  • Appointed as Assistant General Manager, overseeing Blast Furnace Project/Mechanical Maintenance.
  • Managed a furnace with a capacity of 4500m3, producing 8000 tons of hot metal daily.
  • Successfully led the erection and commissioning of conveyors, Slag Granulation Plant, Stoves, Top Recovery Turbine, Dust Catcher System, Pig Casting Machine, and Stock House.
  • Executed hydraulic and mechanical maintenance for the above drives, ensuring smooth operations.
  • Oversaw inventory by ordering precise quantities of stock and executing corrective actions to drive profitability.

Senior Manager

Steel Authority Of India Limited (SAIL)
Durgapur
05.2003 - 05.2008
  • Led comprehensive maintenance and planning activities, including spares planning for consistent rated production of hot metal.
  • Headed the power plant and turbo blowing station.
  • Oversaw maintenance of turbines and boilers, including GE power and SIEMENS turbo blowers with an air delivery capacity of 2,10,000 m3/hr at a pressure of 2.2kg/cm2, for cold blast to blast furnace.
  • Managed large-scale projects and introduced new systems, tools, and processes to achieve challenging objectives and reduce downtime.

Manager

Steel Authority Of India Limited (SAIL)
Durgapur
08.2000 - 04.2003
  • Transferred to the Blast Furnace in August '00 as Manager.
  • Appointed as maintenance in charge of three blast furnaces, capacities of 1800 M3 X 2 and 2400 M3 X 1.
  • Oversaw the production of 7000 to 8000 tons of hot metal daily across all three furnaces.
  • Conducted comprehensive maintenance activities and strategic planning for consistent rated production of hot metal.
  • Spearheaded spares planning to ensure uninterrupted operations.

Deputy Manager

Steel Authority Of India Limited (SAIL)
Durgapur
03.1997 - 07.2000
  • Held the position of maintenance in charge for a 260 tons per hour capacity boiler of RAFACO make (Poland).
  • Conducted comprehensive overhauls, including pressure parts, of the entire boiler.
  • Led overhauls of all auxiliaries, such as coal mill and its gearbox, seal air blower fan, primary air fans with alignment, forced draft fan, and induced draft fans with variable speed hydro coupling.
  • Managed contractual jobs and spearheaded total spares planning and procurement activities.

Assistant Manager

Steel Authority Of India Limited (SAIL)
Durgapur
04.1993 - 02.1997
  • Joined SAIL in May '93, appointed as Assistant Manager at the 2X60 MW Captive Power Plant of Durgapur Steel Plant.
  • Managed turbine and boiler maintenance, overseeing the system supplied by M/S Elektrim, Poland, and erected by M/S Desein (N.D) Pvt. Ltd.
  • Conducted overhauls of turbo generator sets, hydrogen sealing, governing systems, and boiler feed pumps, including gearboxes and hydrocouplings.
  • Ensured complete alignment with motors and managed various auxiliaries such as condensate extraction pumps, governing oil pumps, steam ejectors, HP and LP heating systems, and other power plant drives.
  • Executed alterations to drawings and documentation, including modification of various drives.
  • Led estimation for contractual jobs related to turbine maintenance and spearheaded total spares planning and procurement.

Senior Engineer and Site Incharge

Elektrim SA, Poland
Multiple Places
10.1990 - 03.1993
  • Led commissioning activities for a 3X60 MW power plant at Bokaro Steel Plant.
  • Managed maintenance of the Ash handling system for a 2X110 MW power plant in Jhansi, Parikcha, under UP State Electricity Board.
  • Conducted overhauls and Residual Life Assessments(RLA) of turbine components for a 120 MW turbine at GNDTP Bhantida, Punjab, collaborating with the technical team from M/S Elektrim, Poland.
  • Oversaw the overhaul of a 75 MW hydroelectric power plant, including the generator, in Uckai, Gujarat.

Junior Mechanical Engineer

Desein Pvt. Ltd.
New Delhi
04.1987 - 09.1990
  • Jr. Engineer in 3X60 MW Captive Power Plant at Bokaro Steel Plant.
  • Trained in Design and Drawing, overseeing structural and piping alterations.
  • Fabricated structures and piping, modified drawings from Jan '88 to Oct '88.
  • Installed stainless piping for pneumatic valves and air compressors.
  • Led turbine maintenance, ensuring clearance checks and rectifications per M/S ZAMECH/DOLMEL standards (POLAND).
  • Conducted overhauls of HP/LP valves, governing system elements, and oil tanks.
  • Aligned turbines with generators and coupling before commissioning.

Education

Bachelor of Engineering - Mechanical

National Institute of Technology Karnataka
Surathkal, Karnataka
06.1983 - 03.1987

Skills

    Strategic Planning

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Specialized Achievements

Undergone Operation Training at SAIL, Central Power Training Institute, Rourkela (60 MW Module Plant)

  • Acquired specialized training in power plant operations, enhancing expertise in managing a 60 MW module plant.
  • Demonstrated proficiency in executing operational protocols and ensuring seamless plant performance.

Balancing Expertise - Part-1 Training by IRD Personnel

  • Completed rigorous training on balancing various drives, emphasizing predictive maintenance measures.
  • Applied in-site balancing techniques using IRD machines, showcasing a proactive approach to maintenance.


Boldly Associated with Noteworthy Collaborations

Special Officer for CPP in Collaboration with M/S ABB

  • Appointed as a special officer in collaboration with industry giant M/S ABB for Central Power Plant initiatives.
  • Played a pivotal role in optimizing power plant operations and implementing cutting-edge technologies.

Overhaul of Cooling Tower Fans and FRP Grit Replacement with M/S Paharpur Cooling Towers

  • Spearheaded the overhaul of cooling tower fans, ensuring optimal performance and longevity.
  • Successfully replaced FRP grits in collaboration with M/S Paharpur Cooling Towers, showcasing a commitment to technological advancements.

Erection and Commissioning of RO Water Plant by M/S METCON

  • Led the erection and commissioning of an RO water plant by M/S METCON, supplying 60 tons/hr of purified water to the Durgapur Steel Plant power plant.
  • Demonstrated project management skills and contributed to the enhancement of water supply infrastructure.

Erection of New Boiler (Number 8) by M/S ISJEC Boiler Division

  • Instrumental in the erection of a new boiler (Number 8) by M/S ISJEC Boiler Division at the power plant of Durgapur Steel Plant.
  • Ensured seamless integration of the new boiler into existing operations, showcasing adaptability and engineering expertise.

Timeline

General Manager

Steel Authority Of India Limited (SAIL)
07.2018 - Current

Deputy General Manager

Steel Authority Of India Limited (SAIL)
08.2013 - 06.2018

Assistant General Manager

Steel Authority Of India Limited (SAIL)
06.2008 - 07.2013

Senior Manager

Steel Authority Of India Limited (SAIL)
05.2003 - 05.2008

Manager

Steel Authority Of India Limited (SAIL)
08.2000 - 04.2003

Deputy Manager

Steel Authority Of India Limited (SAIL)
03.1997 - 07.2000

Assistant Manager

Steel Authority Of India Limited (SAIL)
04.1993 - 02.1997

Senior Engineer and Site Incharge

Elektrim SA, Poland
10.1990 - 03.1993

Junior Mechanical Engineer

Desein Pvt. Ltd.
04.1987 - 09.1990

Bachelor of Engineering - Mechanical

National Institute of Technology Karnataka
06.1983 - 03.1987
Malay Kumar MallickGeneral Manager