Rahul Dhiman

> Managing fleet operations in a large-scale nickel mining environment, ensuring optimal performance, safety, and compliance across haul roads. > Implementing advanced Fleet Management Systems (FMS) to enhance operational efficiency, reduce downtime, and optimize resource utilization. > Analyzing fleet data for insights that drive process improvements, safety enhancements, and cost reductions. > Collaborating with cross-functional teams to integrate automation and communication technologies, streamlining production processes. > Leading troubleshooting, system upgrades, and maintenance to ensure real-time monitoring, reliability, and effective decision-making. > Enhancing driver safety through FMS-based safety protocols and training initiatives, fostering a secure working environment. > Contributing to strategic planning for fleet operations, focusing on sustainable and innovative solutions.

Direct the fleet management and dispatch operation across four mine sites — approximately 60 km of haul roads, 656+ units, and 7 contractors — integrating safety, tracking, and dispatch into a single unified system. Established and enhanced 24/7 control rooms with multi-screen dispatch and live monitoring, providing operations with a consolidated, real-time view of site activity. Developed bespoke Python tools and operational web applications to automate manual site processes, improving speed, accuracy, and safety across daily operations. Consolidated data from multiple on-site applications into shared dashboards, aligning fleet, maintenance, and safety information and enabling teams to act without manual report-chasing. Implemented automated speed-control zones and FMS safety protocols and built predictive-maintenance dashboards that flag equipment issues before they escalate to breakdowns. Trained 3,000+ operators and approximately 50 technical staff, ensuring effective adoption of new systems rather than installation alone. Outcome — approximately 95%+ system uptime, a ~40% reduction in safety violations, 2–3-minute dispatch response times, and a measurable improvement in overall fleet efficiency.

>Implementing rigorous safety protocols and fostering an environmentally conscious work culture to ensure a secure environment for all team members. >Integrating cutting-edge technologies into our processing operations to boost efficiency, increase production, and minimize risks in hazardous conditions. >Overseeing a dedicated team managing PLC automated crusher plants, continually updating and configuring the Siemens PLC systems to meet the operational demands and improve process efficiency.

• Enforcing rigorous safety protocols and promoting an environmentally conscious work culture to ensure a secure workplace for all. • Leading a team of 200 personnel responsible for efficient and safe crusher operations. • Integrating advanced technologies into processing operations to boost efficiency, enhance production, and mitigate risks in hazardous conditions. • Overseeing PLC-automated crusher plants, including configuring and updating Siemens PLC systems to meet operational requirements and improve efficiency. • Planning and establishing new control rooms to enhance operational monitoring and control capabilities. • Troubleshooting PLC alarms and events to minimize downtime and ensure uninterrupted operations of automated systems.

>Conducting comprehensive data analysis to identify trends, enabling fleet optimization and cost reduction >Supervising and managing the company's entire fleet of vehicles and equipment for seamless operations >Delivering targeted training and ongoing support to drivers and staff utilizing the fleet vehicles and equipment >Utilizing data from various sources to pinpoint trends, fine-tune mining schedules, and enhance overall mining efficiency >Collaborating with cross-functional teams, including mining crews, maintenance staff, blasting teams, and crusher personnel, to guarantee the timely execution of mining tasks >Maintaining meticulous records of equipment usage, production output, and other crucial performance indicators to facilitate data-driven decision-making.

Designed and commissioned PLC automation for bulk material handling (60,000 TPD) on Siemens and Allen-Bradley platforms, authoring 15,000+ lines of control logic for crushers, conveyors, and screening systems. Developed SCADA/HMI interfaces with live KPIs and alarm management and implemented EN ISO 13849-1 safety interlocks across the process. Delivered the WENCO FMS greenfield implementation and a RAJANT mesh network end-to-end, with fibre-optic backbone and GPS tracking, ensuring reliable fleet data flow across the site. Commissioned 45 variable frequency drives with regenerative braking to reduce energy consumption. Outcome — 96%+ availability, an 8–12% reduction in electrical costs, and approximately 45% less downtime attributable to operator error.

Delivered a fleet management system from design through commissioning for open-pit limestone operations, configuring dispatch and cycle-time logic for excavator–truck coordination. Implemented production and payload monitoring that tightened payload variance from approximately ±15% to ±5% and integrated the VISIO ROCK OCS-4D on-conveyor stone detection system. Developed Power BI dashboards for production, utilization, and fuel analysis, and integrated predictive-maintenance alerts with enterprise systems. Outcome — production increased from 60,000 to 90,000 TPD (~50%) with 99%+ network uptime.

>Diagnosing the root causes of breakdowns and bottlenecks, working closely with the SPM and Electrical teams to devise effective troubleshooting solutions >Implementing safety procedures and promoting environmentally conscious operations, proactively identifying unsafe practices to create a secure working environment for employees >Maintaining seamless communication across sites through the installation and configuration of wireless radio systems >Troubleshooting issues in automated PLC plants, collaborating with third-party companies to resolve errors and minimize downtime >Implementing advanced technology in processing operations to drive innovation, increase production, and reduce risks in hazardous working conditions >Providing training and guidance to team members, fostering best practices to enhance production capacity, quality, and reliability

>Troubleshooting and maintaining PLC systems to guarantee optimal functionality, which includes diagnosing and replacing hardware, addressing software issues, conducting regular maintenance, and implementing upgrades for enhanced system performance >Robust expertise in ladder logic, effectively used for troubleshooting to maintain efficiency and Proficient in identifying potential issues and rapidly devising effective solutions. >Solid understanding of SQL servers for database management and data-driven decision making. >Offering technical support to mining operations personnel by addressing and resolving PLC-related concerns >Delivering training and support to engineers and technicians, promoting proficiency in PLC systems and their effective use.

• Troubleshooting and maintaining PLC systems, including hardware replacements, software issue resolution, regular maintenance, and system upgrades for peak performance. • Collaborating with quarry, maintenance, and operations teams to seamlessly integrate PLC systems with mining equipment and processes. • Managing PLC projects by planning timelines, mitigating risks, overseeing budgets, and ensuring deliverables are completed on time and within budget. • Providing technical support to mining personnel, resolving PLC-related issues to ensure uninterrupted operations. • Delivering training to engineers and technicians, enhancing proficiency in PLC systems and promoting effective utilization.

• Provide technical training to students in different trades at Govt. ITI. • Conducted assessments for Government star projects Implemented by the central government. • Implement government projects at different institutes. • Client Management. • Regular reporting to supervisors. • Documentation and periodic assessments.

>Receiving training on Surface Modulated Device (SMD) machines, gaining practical experience in the operation and maintenance of these devices >Developing skills in creating communication channels over Power Line Carrier Control (PLCC) systems, enhancing the ability to design and implement effective communication networks >Gaining hands-on experience at a leading manufacturer and supplier of telecommunication and IT equipment solutions in India >Acquiring knowledge about a diverse product range, including Voice/Data Multiplexers, Power Plants, Optical/Transmission Equipment, and PLCC.

>>Blasting Operations: Gained expertise in safe and efficient blasting techniques, including planning, execution, and post-blast analysis. >>Minerals Management & Processing: Acquired in-depth knowledge of advanced mineral management and processing techniques, focusing on maximizing resource utilization and ensuring environmental sustainability. >>Mineral Extraction & Transportation: Developed proficiency in modern methods of mineral extraction and transportation, emphasizing logistical efficiency, safety, and cost-effectiveness.

Doctoral research focused on **AI-Driven Semi-Autonomous Fleet and Equipment Integration in Open-Pit Mining for Enhanced Efficiency and Safety**. My work explores the integration of AI, fleet management systems, automation, equipment data, predictive maintenance, dispatch optimisation, and real-time safety monitoring to support safer, smarter, and more efficient open-pit mining operations. The research aims to bridge traditional mining practices with semi-autonomous and future-ready operational systems, improving decision-making, productivity, equipment utilisation, and safety performance across large-scale mining environments.

Lean Manufacturing: Focused on eliminating waste and improving efficiency. I learned to implement lean principles to streamline processes and enhance productivity. Six Sigma and Total Quality Management: Gained expertise in Six Sigma methodologies and quality management principles. Applied these techniques to improve processes and product quality. Supply Chain Management: Developed skills to optimize supply chain operations, ensuring smooth logistics and effective resource management. Project Management: Acquired project management skills to oversee projects from inception to completion, ensuring they are delivered on time and within budget. Sustainable Manufacturing: Explored eco-friendly manufacturing practices, focusing on reducing environmental impact and promoting sustainability in production processes. IoT in Manufacturing: Investigated the application of IoT technologies in manufacturing.