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Summary
Overview
Work History
Education
Skills
Certification
Accomplishments
Languages
Personal Information
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Interests
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Additional Information
Timeline
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MUPPINETI SURESH KUMAR
Open To Work

MUPPINETI SURESH KUMAR

Visakhapatnam,AP

Work Preference

Work Type

Full Time

Location Preference

On-Site

Important To Me

Career advancementHealthcare benefitsWork from home option

Summary

Goal-oriented production manager with extensive experience in coordinating manufacturing processes to ensure timely and budget-compliant product delivery. Expertise in planning production schedules, assessing resource needs, and implementing quality control standards. Proven track record in lean manufacturing and continuous improvement initiatives. Strong leadership skills with a deep understanding of quality standards and safety regulations.

Overview

20
20
years of professional experience
5
5
Certification

Work History

Commissioning

Toyo Engineering India Ltd
Paradip
06.2025 - Current
  • A new PTA-PX Project is in progress at Indian Oil and Corporation Ltd, Odisha, Paradip, Here TOYO Engineering India Pvt Ltd is PMC for PXPTA, ETP and Utility.
  • I joined in this company in the field commissioning for PTA project.
  • Checking and Verifying commissioning plans for new projects, ensuring that all systems are installed and tested according to project specifications.
  • Lead commissioning activities, including system start-up, performance testing, and troubleshooting.
  • Resolve any issues that arise during the commissioning process.
  • Work closely with clients to ensure that their needs and expectations are met throughout the commissioning process.
  • Provide technical support and expertise to project teams and clients during the commissioning phase.
  • Document all commissioning activities, including test results, equipment performance, and any issues that arise.
  • Toyo Engineering India Private Limited (Toyo-India), an Engineering Consultancy & Contracting Company, is a perfect blend of Japanese technology and management practices with Indian expertise and ingenuity.

Manager

PT Indorama Petrochemicals
Cilegon
03.2016 - 06.2024
  • Operated Honeywell DCS system for continuous control of CTA, PTA, and Utility operations at a 500 kta plant in Jakarta.
  • Managed oxidation and hydrogenation processes for CTA and PTA production during retrofit project implementation.
  • Applied hydro testing, pressure testing, and radiographic testing to reduce production costs and increase efficiency.
  • Oversaw daily manufacturing operations, optimizing production schedules and adherence to timelines and budgets.
  • Monitored production processes to ensure product quality, minimize downtime, and comply with regulations.
  • Identified process enhancement opportunities using lean manufacturing techniques and prioritized maintenance activities.
  • Led continuous improvement initiatives such as KAIZEN, 5S, Six Sigma, and TPM while ensuring EHS compliance.
  • Collaborated with quality control to meet standards, implementing corrective actions for deviations.
  • Led team in developing efficient operational strategies for petrochemical production.
  • Coordinated cross-departmental communication to enhance workflow efficiency.
  • Implemented safety protocols and training sessions for all staff members.
  • Analyzed operational processes to identify areas for improvement and optimization.
  • Mentored junior managers in leadership and decision-making skills.
  • Facilitated regular performance reviews to ensure team alignment with goals.
  • Monitored staff performance and addressed issues.
  • Conducted regular meetings with staff to discuss progress and identify areas of improvement.
  • Oversaw daily operations, maintaining efficiency and quality standards.
  • Implemented process improvements, resultingin an increase in operational efficiency.
  • Managed inventory levels to meet demand without overstocking, reducing waste.
  • Proposed or approved modifications to project plans.
  • Implemented quality control measures to uphold company standards.

Deputy Manager

Kanoria Chemicals and Industries Ltd.
Vishakapatnam
05.2010 - 03.2016
  • Operated DELTAV 8.6 for continuous control of Formaldehyde and Hexamine plant processes.
  • Oversaw operations for India's largest Formaldehyde plant with a capacity of 300 TPD in Visakhapatnam.
  • Prepared PFDs, P&IDs, mass balance, and energy balance documentation for plant processes.
  • Configured DCS, including P&ID preparation, instrumentation installation, and process sequence setup.
  • Managed troubleshooting of complex system configurations to ensure optimal operations.
  • Manufactured Formaldehyde, Hexamine, and Resin products efficiently.
  • Administered inventory systems to guarantee timely material availability for production.
  • Developed and implemented new procedures to improve efficiency of the organization.
  • Collaborated with fellow employees, vendors and other parties to achieve smooth coordination of activities, risk remediation and follow-up.

Shift Engineer

Andhra Petrochemicals Ltd.
Vishakapatnam
12.2007 - 05.2010
  • Operated continuous plant utilizing DELTAV 8.4, ensuring efficient and smooth functioning.
  • Led erection and commissioning of Proffenofos project, including eight reactors and one thin-film evaporator.
  • Contributed to OCP and PCP projects, installing two glass lined reactors and four distillation columns.
  • Oversaw setup and commissioning of OCP and PCP systems, achieving 2.8 tons of OCP production.
  • Managed operational readiness of reactors, scrubbers, and distillation columns while meeting safety standards.
  • Manufactured Ortho Chlorophenol, Para Chlorophenol, and Penta Chlorobenzene products.
  • Monitored production processes for safety and efficiency compliance.
  • Coordinated shift handovers to ensure smooth operational continuity.
  • Diagnosed equipment malfunctions and executed timely repairs.
  • Collaborated with maintenance teams to schedule preventive maintenance tasks.
  • Investigated root causes of system failures and implemented corrective actions accordingly.
  • Provided technical support for all engineering staff and personnel.
  • Performed testing to determine functionality or optimization.

Project Engineer

Aarti Industries Ltd.
Vapi
07.2005 - 12.2007
  • Operated a continuous plant through the DCS (Yokogawa Continent Series 1000) system, optimizing unit operations and processes for efficient conversion of raw materials into valuable products.
  • Led development initiatives for higher yield, improved output, and reduced environmental load, driving continuous improvements in production efficiency.
  • Managed the commissioning of new processes and modifications to existing processes, ensuring alignment with company policies on environmental health and safety.
  • Monitored production stages to ensure no adverse material usage variance, adhering to industry standards and environmental regulations.
  • Maintained positive industrial relations, fostering a collaborative work environment for seamless production operations.
  • Handled various engineering equipment across plant operations, ensuring operational readiness and minimizing downtime.
  • Worked with eight distillation columns of varying heights (58m for 4 columns, 42m for 3 columns, and one 32m column), supporting the production of Ortho Nitro Chloro Benzene (50 tons/day), Para Nitro Chloro Benzene (50 tons/day), and Mono Nitro Chloro Benzene (50 tons/day).
  • Supervised crystallization processes for the production of nitro chloro benzene crude, a key input for manufacturing the above products.
  • Manufacturing of Organic Products, All Types of Benzene Products

Education

B.Tech. - Chemical Engineering

Jagannath Institute for Technology & Management
Rourkela, Orissa
01.2005

ClassXII -

S.K.C.G. College
Paralakhemundi, Orissa

ClassX -

GOVT High School
Rayagada, Orissa

Skills

  • Production optimization and process improvement
  • Team leadership and development
  • Performance testing and evaluation
  • Problem solving and troubleshooting
  • Continuous improvement strategies
  • System commissioning and management
  • Safety compliance and risk assessment
  • Standard operating procedures documentation
  • Chemical plant operations expertise
  • Material balance calculations and analysis
  • Petrochemical industry knowledge and practices
  • Root-cause analysis techniques
  • Mass and energy balances proficiency
  • Manufacturing development processes
  • Process flow diagram design skills
  • Separation processes expertise
  • Polymer science knowledge
  • Processing efficiency enhancement
  • Heat transfer principles application
  • Document control systems management
  • Hazardous materials handling expertise
  • DCS operation skills

Certification

  • Aspen Hysys Training, Aharya Technologies Pvt. Ltd., Completed
  • HTRI - Heat Exchanger Design Training, Aharya Technologies Pvt. Ltd., Completed
  • Mini Diploma in Process Engineering, Aharya Technologies Pvt. Ltd., Completed
  • Formaldehyde Process Training, Perstorp Formox, Sweden, Completed, 05/01/10 - 06/30/10
  • KPMG Training, focused on improving work processes, asset reliability, problem-solving tools, and maintenance strategies
  • TPM Training, PricewaterhouseCoopers
  • Lean Six Sigma Black Belt Certification
  • Emerson Process Management (Delta V) DCS Training, Mumbai, Completed

Accomplishments

  • Improved separation processes through automation and enhanced control systems; conducted plant trials for new experimental production methods.
  • Commissioned Hexamine and Formaldehyde plants, increasing Hexamine production capacity from 10 TN/day to 16 TN/day.
  • Implemented various modifications to ensure the plant's safe, smooth, and efficient operation.
  • Led the erection and commissioning of the retrofit project (RPF) at Indorama Petrochemicals Ltd.
  • Completed PTA process retrofit training at Indorama, Thailand.
  • Attended Formaldehyde Process Training (May-June 2010) in Perstorp Formox, Sweden (Technology Provider Training).
  • Received an Appreciation Letter from Kanoria Chemicals and Industries Ltd. for outstanding contributions.

Languages

  • English
  • Hindi
  • Oriya
  • Telugu
  • Bahasa

Personal Information

  • Passport Number: Z7488077
  • Date of Birth: 05/17/82
  • Nationality: Indian

Work Availability

monday
tuesday
wednesday
thursday
friday
saturday
sunday
morning
afternoon
evening
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Software

Aspen Hysys

HTRI

MS office

Languages

Telugu
Native language
Hindi
Advanced (C1)
C1
Oriya
Advanced (C1)
C1
English
Advanced (C1)
C1
Indonesian
Upper Intermediate (B2)
B2

Interests

Production and Operation

Additional Information

Dear Hiring Manager,

I am writing to express my interest in the managerial opportunities within the petrochemical, chemical, and refinery industries. With nearly two decades of experience as a Chemical Engineer, I have honed my skills in plant operations, process optimization, and team leadership, which I believe align well with the requirements of your esteemed organisation. My current role as a Manager at PT Indorama Petrochemicals has equipped me with a robust understanding of managing large-scale production facilities while ensuring compliance with safety and environmental standards.

Throughout my career, I have successfully led various initiatives aimed at improving production efficiency and reducing operational costs. My expertise in DCS and automation, coupled with a strong foundation in project management, has enabled me to oversee significant projects, including the commissioning of major retrofit projects that enhance production capacity. I am particularly proud of my ability to implement lean manufacturing practices and continuous improvement methodologies, which have consistently resulted in enhanced operational performance.

I am eager to bring my innovative solutions and collaborative approach to a forward-thinking company that values growth and excellence. I am confident that my background and commitment to driving continuous improvement will make a meaningful contribution to your team.

Thank you for considering my application. I look forward to the opportunity to discuss how my experience and vision align with the goals of your organisation.

Sincerely,

M. Suresh Kumar

Timeline

Commissioning

Toyo Engineering India Ltd
06.2025 - Current

Manager

PT Indorama Petrochemicals
03.2016 - 06.2024

Deputy Manager

Kanoria Chemicals and Industries Ltd.
05.2010 - 03.2016

Shift Engineer

Andhra Petrochemicals Ltd.
12.2007 - 05.2010

Project Engineer

Aarti Industries Ltd.
07.2005 - 12.2007

B.Tech. - Chemical Engineering

Jagannath Institute for Technology & Management

ClassXII -

S.K.C.G. College

ClassX -

GOVT High School
MUPPINETI SURESH KUMAR