RAHUL KUMAR
Asset Reliability & Sustainability Engineering Professional
Sambalpur,OD
Summary
High-performing Asset Reliability, Sustainability & Utilities Engineering Leader with 11+ years of expertise within the Aditya Birla Group, specializing in driving mechanical reliability, and cost optimization across Cast Houses. Proven expertise in handling industrial gases (Hydrogen, Argon, Nitrogen) and fuels (HFO, Propane), ensuring safe storage, distribution, and adherence to statutory norms including PESO and internal safety standards.
Overview
1
1
Language
5
5
Certifications
11
11
years of professional experience
Work History
Section Head – Mechanical | DC-1,2,4 Casting, Continuous Caster
Hirakud P&S, Hindalco Industries Ltd., Aditya Birla Group
10.2023 - Current
- Asset Integrity & Multi-System Reliability: Command the mechanical reliability, and operational readiness of critical downstream casting infrastructure, including DC Casting, Continuous Casters, heavy-duty EOT cranes, hydraulic systems, high-capacity chillers, and HFO-fired melting/holding furnaces.
- Downstream Quality Optimization & Defect Elimination: Spearheaded a high-impact rolling ingot bend reduction initiative by optimizing casting alignment, significantly improving surface quality and reducing rejection rates for FRP rolling mill.
- Minimized downtime through advanced RCM and shutdown optimization practices, enhancing critical shutdown planning and conducting breakdown delay analysis.
- CAPEX Engineering & Execution: Direct the end-to-end execution of high-risk CAPEX projects valued at ₹15+ Cr, managing everything from initial planning and installation to commissioning and operational stabilization.
- Downtime Minimization & Shutdown Governance: Championed advanced RCM and shutdown optimization practices, leading critical shutdown planning, breakdown delay analysis.
- Critical Spare Governance & Cost Optimization: Oversee strategic vendor development, imported spares localization, and ensure strict OEM adherence while optimizing inventory levels to completely eliminate stock-out situations.
- Led safety governance by implementing safety protocols, reducing risks, and ensuring PTW compliance in hazardous molten metal handling operations, while collaborating with operations, utilities, and quality teams.
Area Head – Reliability, Vendor Development, Improvement Projects | Cast House
Mahan Aluminium, Aditya Birla Group
06.2020 - 10.2023
- Reliability Engineering & CBM: Spearheaded asset reliability strategies and CBM frameworks—including vibration monitoring, laser alignment, and thermography—to maximize Cast House operational performance and minimize unplanned downtime.
- System Improvements & Core Utilities Integrity: Directed complex operations, preventive maintenance, and system optimization for plant-wide utility networks, including high-capacity air compressors, nitrogen generation plants, cooling towers, pump houses, and hazardous gas/fuel infrastructures (Propane, Hydrogen, Argon, HFO, LSHS).
- Strategic Vendor Development & OEM Adherence: Developed vendor relationships and implemented localized import substitution initiatives to reduce OEM obsolescence risks, optimize critical spare inventory, and prevent stock-out situations.
- Energy Management & ISO 50001 Audits: Formulated and executed sustainability and energy efficiency frameworks aligned with ISO 50001 standards, resulting in localized system improvements that reduced utility energy consumption and optimized lifecycle costs.
Area Head – Billet Casting Operations & Mechanical Maintenance
Mahan Aluminium, Aditya Birla Group
01.2020 - 06.2020
- Directed mechanical maintenance and ensured equipment readiness for complex casting infrastructure, including molds, homogenizing furnace, high-pressure hydraulic systems, laydown table, and heavy-duty EOT cranes.
- Revamped PM planning to optimize maintenance response time and enhance long-term equipment reliability.
- Led strategic initiatives to enhance operational efficiency across multiple manufacturing sites.
- Developed and implemented process improvements, resulting in significant cost reductions and increased productivity.
- Mentored and trained cross-functional teams to foster a culture of continuous improvement and excellence.
Shift In-Charge – Wire Rod Mill Operations & Maintenance
Mahan Aluminium, Aditya Birla Group
04.2016 - 01.2020
- Looked after Operation & Maintenance of Wire Rod Mill
- Reliability & Breakdown Analytics: Executed comprehensive RCA, Pareto analysis, and delay analysis on critical breakdowns to successfully minimize repetitive mechanical issues and optimize asset MTBF/MTTR.
- Spearheaded initiatives for fuel efficiency improvement through burner tuning and furnace process optimization, achieving benchmark reduction in HFO consumption.
- Partnered with cross-functional teams to optimize process parameters, expanding in-house product portfolio and enhancing overall operational capability.
- Safety & Operational Governance: Enforced rigorous shift-level mechanical safety protocols, Permit to Work (PTW) compliance, LOTOTO, and operational discipline across all WRM operations to maintain zero-incident workflows.
Graduate Engineer Trainee (GET)
Aditya Aluminium, Aditya Birla Group
07.2015 - 04.2016
- Commissioning & Plant Ramp-Up: Contributed to greenfield commissioning and operational ramp-up phases of Green Anode Plant (GAP), ensuring readiness for production.
- Equipment O&M: Managed operations and mechanical maintenance for heavy material handling systems, optimizing performance of conveyors, crushers, classifiers, and ball mills.
- Equipment O&M: Handled operations and mechanical maintenance for heavy material handling systems, including conveyors, crushers, classifiers, and ball mills.
- Process Exposure: Acquired technical exposure to carbon plant operations, including baking furnace maintenance and fume treatment systems, enhancing understanding of production processes.
Education
B.Tech - Mechanical Engineering
Motil Nehru National Institute of Technology (MNNIT)
Allahabad01-2015
Skills
Cast House O&M (DC casting, Continuous Caster, Wire Rod Mill, Billet Casting)
RCM, CBM, FMEA & RCA
Resource optimization (energy & water)
Energy Management System- EnMS 50001
Statutory compliance (PESO, CPCB, SPCB)
Water treatment systems-Scaling, corrosion, biological control
Hazardous material( Propane, Hydrogen, Argon, Nitrogen) storage & handling
Environmental Risk & Safety Compliance
Spare Inventory Optimization & Critical Spare Listing
Asset Reliability & Maintenance Strategy
Mechanical Reliability Engineering
Material Handling Optimization
Process Stabilization & Product Defect Reduction
System Improvement & Governance
Capital Project Oversight
Project Management & Strategic Leadership
Stakeholder collaboration
Maintenance cost reduction
Safety risk assessment
Horizontal Replication of Best Practices
Certification
EnMS-Energy management System- Lead Auditor-LRQA – ISO 50001
Timeline
Section Head – Mechanical | DC-1,2,4 Casting, Continuous Caster
Hirakud P&S, Hindalco Industries Ltd., Aditya Birla Group
10.2023 - Current
Area Head – Reliability, Vendor Development, Improvement Projects | Cast House
Mahan Aluminium, Aditya Birla Group
06.2020 - 10.2023
Area Head – Billet Casting Operations & Mechanical Maintenance
Mahan Aluminium, Aditya Birla Group
01.2020 - 06.2020
Shift In-Charge – Wire Rod Mill Operations & Maintenance
Mahan Aluminium, Aditya Birla Group
04.2016 - 01.2020
Graduate Engineer Trainee (GET)
Aditya Aluminium, Aditya Birla Group
07.2015 - 04.2016
B.Tech - Mechanical Engineering
Motil Nehru National Institute of Technology (MNNIT)
Awards & Professional Recognition
Aditya Birla Awards "Emerging Professional" Winner (2019)
Executive Representation (Shillim Summit): Handpicked alongside the Plant Head as the exclusive two-member delegation representing Hindalco Mahan at the Shillim Leadership Event (Alibaug–Mumbai, 2019); successfully drove the implementation of summit-derived operational action plans across plant facilities.
PRIDE Award Winner: Recognized for engineering innovation leading to a successful Bearing Life Enhancement Project.
Won CII National Maintenance Circle (2021): Best Case Study for technical excellence and maintenance strategy execution.
Technical Tools
- Oracle ERP
- Advanced MS Excel & PowerPoint
- MATLAB
- Fusion360
- Pilog
Additional Information
- Home Town- Mainpuri, Uttar Pradesh
- Current Location: Sambalpur, Odisha