O S C VIMAL BABU B.E.,M.S.,
Jharsuguda
Summary
- Results-driven senior-level Large-Scale Manufacturing Plant Operations Manager and engineer armed with a graduate degree and 16 years' experience.
- Dedicated to improving efficiency, productivity, and profitability of organizations through the development and execution of innovative, cost-effective solutions.
- Adept at leading teams in the optimization of processes and procedures within manufacturing plants.
- A Turnaround Specialist in business continuity & sustainability, cost optimization, capacity improvement, minimizing process validation, power consumption, digitalization, quality and improving customer experience Stake holder's engagement by supporting and influence internal & external
- stakeholder's towards Mission & Vision of organization Experienced Manufacturing Engineer and Internal Energy & IMS Auditor with a background in leading process improvement initiatives and managing high quality metal introductions.
- Expert in Lean Six Sigma, Minitab,Power BI and database management. Successfully reduced SPC of aluminium by 15%, COP V2 cost 15$ per year through lean manufacturing processes.
- Seeking a Leading role of large scale industry and Internal Auditor position at a company where I can leverage my process improvement and quality management skills to drive results.
Overview
16
16
years of professional experience
1
1
Certification
Work History
Operation & Production Process Lead
Vedanta Aluminium Ltd.
Jharsuguda
04.2019 - Current
- VALJHA,is the world largest aluminium producer in the single loaction
- Specific energy consumption of aluminium per metric ton reduced from 14000kwhr to 13450kwhr by process parameter optimization and technology upgradation
- Vedanta Lining designed which is achieved to reduce energy by 200kwhr/MT
- SMART Pot digitilization implemented with gain of 10$ reduction in V2 Cost of the COP
- Created technical documents, risk and opportunity details & certified ISO 50001/2018 Energy policy
- Digitized process gaps tracking system resulting in 200% increased operator participation in 5 weeks
- Dream Run & Vardhan Title winner.
- Managed multiple simultaneous projects within tight deadlines while consistently meeting or exceeding expectations for quality and timeliness.
- Collaborated closely with engineers on various process improvements that led to significant reductions in equipment downtime.
- Participated in continuous improvement programs to drive innovation and optimize overall operational efficiency across the facility.
- Enhanced production efficiency by optimizing machine settings and streamlining processes.
Production Process Incharge & Auditor
Vedanta Aluminium Ltd.
08.2014 - 03.2019
- As the process lead of an Aluminum Production Plant (smelter) with a production capacity of 5.5 LTPA, my responsibilities included ensuring safe operations in the Pot Room, overseeing aluminum production, managing quality, and implementing industry best practices
- Focusing on manpower productivity and improving quality production were key aspects of your role
- Managed 24/7 process improvement, monitored all shift activities, and implemented process enhancement strategies
- Training 180 new graduates in industrial safety and technical skills represents a notable achievement
- My work aids in cultivating a competent workforce and promoting safety protocols
- A detailed structure for collaborative work and improvement initiatives has been prepared in conjunction with experts from McKinsey, PwC, and BEE.
- Provided detailed documentation on audit findings, facilitating swift corrective action when necessary.
- Maintained confidentiality, handling sensitive information discreetly throughout all stages of the audit process.
- Streamlined audit processes, improving efficiency and reducing time spent on each audit engagement.
- Followed established auditing processes to meet internal and regulatory requirements.
Shift Engineer
VAL
02.2008 - 09.2014
- Shift Crews to Shift Incharge
- Pot room operation activities include pot management, anode changing, anode covering, beam raising, metal tapping, and more
- Implementing the 5S methodology in the workplace
- I am a certified Six Sigma Yellow Belt and have successfully completed projects using the DMAIC methodology
- Establish, review, and update Standard Operating Procedures, training manuals, raw materials, and processing materials.
- Reduced waste generation through continuous process improvement initiatives and diligent monitoring of resource consumption.
- Streamlined workflow processes, optimizing staff allocation during peak production hours for increased productivity.
Education
MS Manufacturing -
BITS Pilani
Jharsuguda, Odisha09.2015
Bachelor of Engineering in Electrical -
Anna University
05.2007
Skills
- Leading big team
- Excellent Communication
- Operational Efficiency Team Player
- Goal Oriented Self Driven
- Flexibilty & Adaptability
- Process Control Expertise
- Waste Reduction
Certification
- Internal Energy Auditor
- QMS Auditor
- 5'S Internal Auditor
- AO Auditor
Accomplishments
- Recognized three times as the best technical in-charge for demonstrating voltage reduction and improving shift manpower productivity.
- Dream Run location achieved
- Achieved the highest-ever current efficiency of 95.15% in FY 23.
Languages
English
Hindi
Tamil
Sourashtra
Awards
- CEO Kitty Award
- Successfully achieved metal production of FY23 by 5% increment of the BP
- CII Awards- Energy Efficient Unit FY22
- Best Technical prsentation done in fives internation conferencesIBAAS,INCAL & JNTU
Projects
- Production Current Efficiency Improvement,FY21 - Improving Cathode Current Efficiency through Operational Excellence and Process Optimization The project received a CE improvement from 93.5% to 95%, resulting in a 2% increase in metal production for the year, along with a resultant energy saving and a $5 reduction in v2 cost per EBITDA.
- Reduction of Specific Energy Consumption (kwhr/MT), FY23 - Through process trials and modification of the work schedule, the energy consumption per ton of aluminum can be reduced. A reduction of SPC by 20 units per metric ton of aluminum leads to a $2 benefit in COP.
Timeline
Operation & Production Process Lead
Vedanta Aluminium Ltd.
04.2019 - Current
Production Process Incharge & Auditor
Vedanta Aluminium Ltd.
08.2014 - 03.2019
Shift Engineer
VAL
02.2008 - 09.2014
MS Manufacturing -
BITS Pilani
Bachelor of Engineering in Electrical -
Anna University