Mallik Rao

a) Strategic Leadership: I am a strategic member of the Executive Committee, responsible for presenting monthly mill performance reports to the Board of Directors. b) Operational Optimization: I orchestrate seamless mill operations, optimizing resources to enhance efficiency & streamline production processes. My focus is on delivering operational excellence at every level. c) Financial Stewardship: With precise control over annual Capex & Opex budgets, I align financial strategies with organizational objectives, ensuring that resources are allocated efficiently & cost-effectively. d) Strategic Initiatives: I am an integral part of the core group for mill strategic management, where I drive forward-thinking initiatives aimed at enhancing competitiveness, sustainability, & market leadership. e) Compliance Assurance: I serve as the Management Representative (MR) for diverse certifications, including ISO, OSHAS, & GREEN PROPER, ensuring unwavering compliance with industry standards & regulations. Notable Projects: a) Chloride Potassium Removal Project (CRP): I have led the Chloride Potassium Removal Project, focusing on improving chemical processes critical to production efficiency & environmental compliance. b) Emergency Backup Power: As the leader of the Emergency Backup Power project, I have ensured reliable power supply for the mill, minimizing downtime risks & maintaining uninterrupted operations. c) Cooking Process Enhancement: I have co-led the modification of the G2 to G3 cooking process, optimizing the pulp production process & enhancing product quality. d) Capital Investment Management: I am responsible for preparing & shortlisting Capex proposals. e) Efficiency Improvement: My initiatives include improving overall Operational Line (ODL) efficiency & optimizing the log-to-pulp ratio, enhancing resource utilization. f) SAP Implementation: Led the implementation of SAP-PM & Project Module, modernizing maintenance practices & project management.

a) Annual Outage Total Management: I excel in coordinating & overseeing all aspects of annual outages, from daily coordination to budgeting & cost control, ensuring the efficient execution of essential maintenance activities. b) Capital & Maintenance Budgeting: I have a proven track record of budgeting & controlling capital & maintenance expenditures, aligning financial strategies with organizational goals. c) Chipping Plant Optimization: I successfully improved Chipping Overall Equipment Efficiency (OEE) from 65% to an impressive 90%, a testament to my commitment to enhancing operational efficiency. d) Vendor Development: I have a strong focus on vendor development, cultivating new relationships to exp& the organization's supplier network & enhance procurement capabilities. e) Standardization & Inventory Reduction: I championed the standardization of consumables throughout the mill, resulting in reduced inventory levels & lower carrying costs, contributing to cost savings. f) Motor Reliability: Through strategic changes in motor rewinding contracts, I significantly reduced motor burns, enhancing equipment reliability & reducing maintenance costs. g) Insurance Program Coordination: I oversee comprehensive insurance programs for the mill, ensuring robust coverage & risk management. Key Projects: a) New ESP for RB (Electrostatic Precipitator): I led the implementation of a new Electrostatic Precipitator to enhance air quality control & environmental compliance. b) Sheet Break Reduction: I initiated projects aimed at reducing sheet breaks in the pulp dryer, improving production efficiency & product quality. c) Chipping Plant Efficiency: I successfully improved the efficiency of the chipping plant & enhanced debarking processes, increasing overall productivity. d) Equipment Monitoring Digitization: I played a pivotal role in the digitization of equipment monitoring, leveraging Infinite Uptime's IDAP technology to enhance maintenance practices & equipment reliability.

During my tenure as Manager Mechanical Projects for the Asia Pulp and Paper (APP) - Sinarmas – OKI Project, I played a pivotal role in establishing and maintaining operational reliability in one of the largest pulp manufacturing facilities in Indonesia. This significant undertaking encompassed overseeing a greenfield project, commissioning, and sustaining peak mechanical performance. Key Responsibilities: a) Project Techno-Commercial Leadership: From 2015 until project commissioning, I assumed responsibility for project techno-commercial negotiations, ensuring the project was financially sound while meeting technical excellence standards. b) Leadership Excellence: Leading a diverse team of 14 expatriates and 60 local employees, I orchestrated seamless collaboration to successfully complete the project, emphasizing reliability as a cornerstone of our approach. c) Technical Issue Resolution: I played a vital role in resolving complex technical issues during project construction, ensuring a smooth transition to operational phases. d) Post-Commissioning Mechanical Maintenance: Following project commissioning, my focus shifted to mechanical maintenance, encompassing two fiber lines, two pulp machines, and nine chipping lines. Major Contributions: a) Record Time Greenfield Commissioning: Under my leadership, the greenfield project was commissioned successfully in record time. This achievement showcased our commitment to efficient project execution. b) Mill Sustainability: To ensure sustainable operations, I designed and implemented a mill running plan that included the recruitment and training of 80 graduate trainees. This initiative not only addressed immediate operational needs but also nurtured future talent. c) Optimized Maintenance Organization: I established a robust maintenance organization by recruiting a blend of local and expatriate experts. This approach allowed us to leverage both local knowledge and international best practices.

As Manager Mechanical and Reliability at International Paper (IP), I drove initiatives to improve operational reliability, minimize unplanned downtime, and streamline maintenance practices. Key Responsibilities: a) Global Reliability Road Map: Implemented a roadmap aligning local practices with global reliability standards, fostering a culture of excellence and enabling sustainable growth. b) Precision Maintenance: Introduced IEPM and MPM practices, extending asset life, enhancing efficiency, and reducing costs. c) Improvement Projects: Led cross-functional projects that reduced unplanned downtime, improved equipment reliability, and enhanced operational efficiency. d) SAP PM Module: Successfully implemented the FISCM – SAP PM Module project, streamlining maintenance management and enabling data-driven decisions. e) Motor Reliability: Achieved a 30% reduction in motor burns, enhancing equipment reliability and supporting sustainability goals. f) Reliability Workshop: Established a workshop for MPM, promoting a culture of continuous improvement and knowledge sharing. Achievements: a) 15% Reduction in Unplanned Downtime: Enhanced production efficiency & overall equipment effectiveness (OEE). b) Improved Equipment Longevity: Precision maintenance reduced maintenance & replacement costs, improving reliability and cost savings. c) Efficient SAP PM Module Implementation: Streamlined maintenance operations, improved work order processing, and enabled data-driven decisions. d) 30% Reduction in Motor Burns: Enhanced equipment reliability, reduced costs, and supported sustainability goals. e) Reliability Workshop Impact: Fostered a culture of continuous improvement, ensuring top reliability standards.

Key Responsibilities: a) Maintenance Excellence: I took charge of ensuring mechanical maintenance excellence, focusing on fiber line systems. This encompassed preventive and corrective maintenance to ensure uninterrupted operations. b) Capex Project Management: I managed a significant capex project valued at $80 million aimed at upgrading the PM8 pulp line, resulting in a substantial increase in pulp production by 200 tons per day. c) Efficiency Enhancement: Led to a remarkable 75% reduction in mechanical loss time, significantly improving overall operational efficiency. d) Cost Optimization: Reduced mechanical maintenance costs from $25 to $20 USD per ton through efficient maintenance practices and process improvements. e) Reliability Improvement: Achieved a remarkable 90% reduction in mechanical seals failure, demonstrating a strong commitment to enhancing reliability. f) Capacity Expansion: Oversaw the successful commissioning of a capacity upgrade project, increasing the PM8 fiber line's capacity from 2000TPD to 3100TPD. g) RCM Implementation: Implemented Reliability-Centered Maintenance (RCM) practices across all fiber lines, optimizing equipment reliability and performance. Key Achievements: a) Zero Downtime Streak: Achieved a remarkable six consecutive months of zero downtime, a testament to the effectiveness of our maintenance and reliability initiatives. b) Special Recognition: Recognized with a special reward from Mill Management. c) Mechanical Seal Success: Achieved a 90% reduction in mechanical seal failures, underscoring our dedication to reliability and operational continuity. d)Cost Savings Initiative: Led a special Continuous Improvement (CI) project aimed at reducing costs associated with mechanical seals, resulting in significant savings. e) Notable Projects: My leadership extended to critical projects, including the upgrade of the G2 digester to G3 & the addition of an extra fiber line in PM8, boosting production by 1000TPD.

My role as Mechanical Manager exemplified the critical role of reliability & continuous improvement. It required a strategic blend of leadership, technical expertise, & a commitment to operational excellence. Key Responsibilities: a) Strategic Maintenance Management: Strategically managed the mechanical maintenance of the fiber line & its ancillaries, ensuring uninterrupted operations while adhering to high st&ards of reliability. b) Continuous Improvement: Engineered a culture of continuous improvement, leading to an impressive 80% reduction in mechanical downtime & substantial cost savings. c) Energy-Saving Strategies: Implemented innovative energy-saving strategies, particularly in optimizing the use of process pumps, contributing to both cost efficiency & sustainability. d) Gas Emissions Control: Improved gas emissions control through enhancements to the scrubbing system, limiting emissions to a minimum extent & promoting environmental responsibility. Major Contributions: a) Reliability Improvement: Achieved a remarkable 95% reduction in mechanical seals failures, demonstrating our dedication to enhancing equipment reliability & operational continuity. b) Downtime Reduction: Through meticulous planning & efficient maintenance practices, I successfully reduced mechanical downtime by an impressive 80%, significantly enhancing operational efficiency. c) Cost Savings: Led initiatives that resulted in a notable reduction in mechanical maintenance costs, from 225 Rs/T to 175 Rs/T, contributing to the company's financial sustainability. d) Environmental Responsibility: My work on improving the scrubbing system played a pivotal role in limiting gas emissions to a minimum extent, aligning our operations with environmental compliance & responsibility. Notable Projects: a) D2 Stage Bleaching Erection & Commissioning: I successfully managed the erection & commissioning of the D2 stage bleaching project, underscoring my ability to lead critical projects effectively.

In this role, at RAPP, one of the world's largest pulp & paper producing companies, I was entrusted with overseeing critical mechanical maintenance operations within an industry-leading environment. Key Responsibilities: a) Preventive & Predictive Maintenance: I was responsible for the meticulous preventive & predictive maintenance of a 7500 T/Day capacity fiber line & its associated accessories, ensuring continuous operations & peak equipment performance. b) Reliability-Centered Maintenance (RCM): Successfully implemented reliability-centered maintenance practices, significantly enhancing equipment reliability & minimizing unplanned downtime. c) Bearing Failure Reduction: Achieved a remarkable milestone by reducing bearing failures in the Twin-roll press to zero. d) Lubrication Cost Savings: Through the implementation of better maintenance practices, I reduced lubrication costs by 20%, contributing to cost efficiency without compromising equipment performance. e) Condition Monitoring Enhancement: Improved preventive maintenance by implementing advanced condition monitoring techniques, optimizing equipment health assessment. f) Cutting-Edge Technology Adoption: Introduced the latest condition monitoring software to analyze equipment condition through vibration monitoring, providing actionable insights for proactive maintenance. Major Achievements: a) Zero Bearing Failures: My relentless efforts resulted in zero bearing failures in the Twin-roll press. b) Cost Savings: Achieved substantial cost savings by reducing lubrication costs by 20% while maintaining equipment performance at peak levels. c) Reliability: The successful implementation of RCM practices significantly enhanced equipment reliability, contributing to uninterrupted operations. d) ACM: The adoption of state-of-the-art condition monitoring software improved our ability to analyze equipment condition, enabling proactive maintenance strategies.

My role as a Reliability and Mechanical Expert at Trident, Abhishek Industries, underscored the critical intersection of project management, mechanical expertise, and operational excellence in the pulp and paper manufacturing industry. Key Responsibilities: a)Project Leadership: I spearheaded a range of pivotal projects, including the erection of a 250 TPD Paper Machine supplied by Allimand, the installation of a 250 TPD Wheat Straw-based pulp mill by Metso, and the setup of a 6 TPD capacity Clo-2 generation plant by EKA chemicals. My role extended to the erection of a 300 N-M3 Oxygen generation plant supplied by M/s. MVS Engineering. b) Renovation and Transformation: I led the renovation of an existing old pulp mill, transforming it from wheat straw processing to hard wood pulp production, contributing to operational modernization and sustainability. c) Technical Negotiations: I was responsible for all technical negotiations and quality compliance with multiple vendors, ensuring the highest standards of equipment and material quality. d) Quality Assurance: I maintained stringent quality compliance throughout fabrication activities at the project site, guaranteeing adherence to industry standards and specifications. e) Cross-Functional Collaboration: I collaborated seamlessly with foreign erection supervisors, various team agencies, and suppliers, ensuring effective coordination and timely project delivery. f) Supplier Management: I managed material follow-ups with suppliers, optimizing procurement processes and streamlining supply chain management.

During my remarkable ten-year journey at ITC-Limited, PSPD Unit, Bhadrachalam Division, I embarked on a mission to champion reliability, mechanical excellence, and operational efficiency within the dynamic world of pulp manufacturing. Key Responsibilities: a) Mechanical Maintenance Leadership: I assumed the crucial role of overseeing mechanical maintenance activities across diverse areas, including the fiber line, chipper house, digester house, ClO2 generation plant, oxygen generation plant, secondary fiber treatment plant, and pulp sheeting machine. My responsibilities extended to planning, scheduling, budgeting, and the seamless execution of maintenance and overhaul activities. b) Zero Mechanical Downtime: Through unwavering commitment and meticulous planning, I achieved an unprecedented record of zero mechanical downtime in a single year, underscoring the reliability and resilience of our operations. c) TPM Implementation: I successfully implemented Total Productive Maintenance (TPM) practices across the entire fiber line and its accessories, ensuring optimal equipment performance, minimal downtime, and maximum productivity. d) Innovative Techniques: I spearheaded the application of advanced techniques, including the use of JQI (Justification for Quality Improvement) methodologies, which led to a remarkable 30% reduction in bearing consumption annually. e) Reliability-Centered Maintenance (RCM): I played a pivotal role in the successful implementation of Reliability-Centered Maintenance (RCM) practices, enhancing equipment reliability, and optimizing maintenance strategies. f) Condition Monitoring: Leveraging cutting-edge condition monitoring techniques such as Spectrum analysis and oil analysis, I reduced equipment failures and ensured peak performance. g) Mechanical Seal Expertise: I achieved an outstanding 95% reduction in mechanical seal failures, exemplifying our commitment to maintaining equipment integrity and operational continuity.