Rahul Naik

• Process Optimization:
  
  Reduced Drying Time: Implemented blower-based optimization, resulting in significant reduction of drying time.
  
  Optimized Distillation Cycle: Integrated bubble point temperature instrument interlocking, decreasing distillation time cycle and improving process efficiency.
  
  Minimized Solvent Loss: Re-engineered utilities and operations philosophy to effectively reduce solvent loss, enhancing cost-effectiveness and reducing waste.
  
  Lowered Electricity Consumption: Conducted energy mapping and installed VFDs (Variable Frequency Drives) in utility assets, achieving a reduction in electricity consumption.
  
  Reduced Boiler Fuel Consumption: Maintained optimal combustion rates using instrumentation interlocking, leading to a reduction in briquette fuel consumption for boiler operation.
  
  Improved Reaction Conversion: Installed instrumentation interlocks that improved reaction conversion rates, optimizing overall production efficiency.

• Process Design and Review:
  
  Prepared and reviewed Process Flow Diagrams (PFD), Piping and Instrumentation Diagrams (P&ID), Utility Flow Diagrams (UFD), and Utility Network Diagrams for the processing unit.
  
  Conducted detailed Material & Energy Balance calculations and analysis to optimize utility and chemical consumption for the processing unit.
  
  Equipment Design and Documentation:
  
  Responsible for the preparation and review of equipment sizes, layouts, and piping layouts where applicable.
  
  Developed and reviewed equipment process data sheets, instrument process data sheets, and specifications for brought-out items.
  
  HAZOP Study Execution:
  
  Led the HAZOP Study for the processing unit to identify and mitigate risks associated with process design and operations.
  
  Utility & Chemical Consumption Analysis:
  
  Conducted analysis of utilities and chemicals consumption, contributing to cost optimization and improving operational efficiency.
  
  Key Skills Utilized:
  Process Design & Engineering
  
  P&ID, PFD, UFD, and Utility Network Diagram preparation
  
  HAZOP Study Facilitation & Risk Management
  
  Material & Energy Balance
  
  Equipment Layout and Design
  
  Technical Documentation & Specifications
  
  Utilities & Chemicals Optimization

• Distillation Operation Optimization:
  
  Successfully reduced batch time cycle for distillation operations, increasing overall plant throughput and operational efficiency.
  
  Solvent Loss Reduction in Reaction Distillation:
  
  Implemented process adjustments to reduce solvent loss in reaction distillation, leading to cost savings and improved resource utilization.
  
  Improved Steam Economy in Multi Effect Evaporators:
  
  Enhanced steam economy in Multi-Effect Evaporators through process modifications, resulting in lower energy consumption and improved operational cost efficiency.
  
  Data-Driven Process Optimization:
  
  Utilized Python programming to analyze process data from the database, leading to improved reaction conversion and increased selectivity in chemical reactions.
  
  Key Skills Utilized:
  Process Optimization & Improvement
  
  Batch Process Management
  
  Distillation & Reaction Distillation
  
  Multi-Effect Evaporator Optimization
  
  Python Programming for Process Data Analysis
  
  Energy Efficiency Improvements
  
  Cost Reduction & Resource Management

• Pilot Plant Operations & Scale-Up:
  
  Managed pilot plant operations for scaling up chemical processes, including Bromination, Chlorination, and HF HALEX Reaction from R&D to full-scale production.
  
  Led piloting to scale-up for Bromination, Chlorination, and HF HALEX reactions ensuring smooth transition from laboratory-scale processes to commercial production.
  
  Greenfield Project Leadership:
  
  Led process engineering efforts in a greenfield project, solving troubleshooting issues during erection and commissioning, ensuring adherence to safety and operational standards.
  
  Successfully managed the process validation batch completion according to technology licensor’s specifications, ensuring the plant met design and operational parameters.
  
  Troubleshooting and Process Optimization:
  
  Directed troubleshooting activities, providing technical solutions to operational challenges during the startup and commissioning phases, ensuring a smooth plant ramp-up.
  
  Collaboration with R&D and Technology Licensors:
  
  Collaborated closely with R&D teams to facilitate scale-up processes and worked with technology licensors to ensure the plant adhered to design specifications during commissioning and validation.
  
  Key Skills Utilized:

• Unit Operations & Process Handling:
  
  Managed and operated key unit operations including Batch Reactors, Packed Distillation Columns, Centrifuges, Nutch Filters, Tray Dryers, Multi Mills, RCVD, and Micronizers, ensuring smooth and efficient process flow.
  
  Regulatory Compliance & Documentation:
  
  Ensured adherence to GMP (Good Manufacturing Practices) and CGMP (Current Good Manufacturing Practices) as per USFDA requirements, maintaining high standards of documentation and facility operations.
  
  Led the documentation and compliance activities for production processes, ensuring that all records met regulatory and quality standards.
  
  PPA & Intermediate Area Management:
  
  Worked extensively in the PPA (Production Process Area) and Intermediate Areas, ensuring safe and compliant operations according to regulatory guidelines.
  
  Shift Operations & Team Leadership:
  
  Managed shift operations as Shift Incharge, overseeing day-to-day activities, ensuring safe operations, and troubleshooting any issues in the production process.
  
  Led the plant operations as Plant Incharge, supervising plant activities, coordinating with cross-functional teams, and ensuring that production targets were met efficiently.
  
  Process Optimization & Troubleshooting:
  
  Played an active role in troubleshooting unit operations, ensuring that equipment and processes were operating at peak efficiency, minimizing downtime and optimizing resource utilization.
  
  Key Skills Utilized:
  Unit Operations: Batch Reactors, Distillation, Centrifuges, Nutch Filters, Tray Dryers, Multi Mills, RCVD, Micronizers
  
  GMP & CGMP Compliance (USFDA Requirements)
  
  Documentation & Regulatory Compliance
  
  Shift & Plant Operations Management
  
  PPA & Intermediate Area Management
  
  Troubleshooting & Process Optimization
  
  Leadership & Team Coordination

Unit Operations & Unit Processes:

Gained comprehensive knowledge in unit operations and unit processes, developing a strong foundation in process handling and equipment operations.

Regulatory Documentation & Change Control:

Developed proficiency in BMR (Batch Manufacturing Records), ECR (Engineering Change Requests), Change Control Documentation, and Deviation Documentation, ensuring compliance with quality standards.

Assisted in New Product Line clearance, ensuring smooth transitions and effective documentation during product introduction.

PPA & Intermediate Area Operations:

Gained hands-on experience in PPA (Production Process Area) and Intermediate Area working activities, understanding the operational flow and regulatory requirements for these areas.

Batch Planning & Reporting:

Learned and assisted in the creation of Batch Plans, RM (Raw Material) Plans, and DPR (Daily Production Reports), ensuring effective production scheduling and material management.

Process Optimization & Bottleneck Removal:

Actively participated in de-bottlenecking activities to identify and address process inefficiencies, improving overall production throughput and reducing cycle times.

Key Skills Utilized:
Unit Operations & Unit Process Knowledge

BMR, ECR, Change Control, and Deviation Documentation

New Product Line Clearance

PPA & Intermediate Area Operations

Batch Planning & RM Planning

DPR Reporting & Process Optimization

De-bottlenecking & Efficiency Improvement