Rajendra Acharya

Plant Operations, team management, Strategic business planning, Growth - Capex / expansion planning, New Product Development, Productivity projects, Cost management, PL accountability

Engineering and Maintenance Head for 1050 TPD Maize Starch and derivatives plant

Purpose of the Job: Maximizing the effectiveness of Engineering and Technology department, towards realizing the Organizational objectives by increasing the uptime, reliability and Speed of machines, by innovating and automizing, by reducing costs through alternative Ideas, alternative vendors and so on. Key roles & responsibilities: Building Maintenance plan at the start of the year along with Production heads mapping order forecasts, production annual lifecycle and customer need assessment. Finalizing Maintenance Budget with due approvals at the start of FY to cater effectively to the plant utilization. Ensuring Implementation of Line and Lean Maintenance Practices & Cost reduction activities, Innovative ideas for modification for reducing cycle time and enhancing productivity. Monitoring Major Project Activities i.e. setting up production lines, installation and commissioning of new equipments in plant premises Building balanced maintenance portfolio of planned and corrective maintenance. Strongly emphasizing on autonomous and design-out maintenance and RCM analysis Ensuring learning environment & training schedules of Maintenance personnel on TPM principles and cross-board training are strictly followed. Ensuring SHE compliances at the workplace Doing Periodic Performance reviews, feedback and counseling of the entire team End to end projects management Annual energy audits and identification of energy conservation areas with achievement of target set.

on Deputation in SGCMBPL as operatins Head

 Heading Operations of a Silicon Carbide plant of approximately 180 employees. Responsible for P& L accountability of the plant.  Shouldering the responsibility for seamless, efficient functioning of all production and supporting activities to achieve top line and profit objectives.  Liable for the following direct reports: Production, Procurement, maintenance, engineering, quality assurance, Environment Health and Safety, WCM, Projects.  Liaising with authorities like PCB, Factory inspectors, etc for statutory and legal compliance.  Actively participates in the budget process and control expenditures within budget.  Responsible to analyze workforce requirements; conduct performance appraisals and provide coaching and guidance to all employees; encourage operating in a continuous improvement environment.  Accountable to remove production constraints; allocate human and equipment resources and direct production employees to attain all established goals.  Review/update standard operating procedures on a periodic basis to control operation activities as per ISO 9000, ISO 14000 and OHSAS 18000 standards.  Managing the Logistics and supply chain - resulting delivering on commitments to customers

Chennai Group Technical Head Key Highlights Led team of Engineers from different divisions along with partners. Instrumental in evaluating architectural and automotive glass processing capacity enhancement opportunities for the plant. Spear headed the complete architecture glass processing plant in Hyderabad from foundation to production. Shouldered responsibility of making maintenance strategy of glass processing Equipments like tempering plant, Laminating glass, Insulated and printed glass based on the condition and quality production requirements. Pivotal in upgrading glass processing machines to improve quality, productivity, energy efficiency and reliability. Pondichery (HNG group) Manager-Engineering Key Highlights Spearheaded Mechanical Department with 35 member’s team consisting of Engineers and Technicians. Instrumental in planning & coordinating for all the maintenance activities as per calendar. Administered activities like contractor’s selection, techno-commercial evaluation of plant, up gradation projects, etc. Efficiently commissioned 2nd Batch Feeding Conveying System to enhance Glass Melting Furnace throughput by 20%. Pivotal in relocating 6.3 MW Furnace Oil based Mirlees DG Set from Kolkata and administered installation in Pondicherry factory. Managed various civil activities for power plant comprising building modification and machinery foundation.

maintenance management project management Contiunous imrovement Energy saving initiatives

Key Highlights Managed activities of Service Department along with a team of 40 members including Technicians, Supervisors and Engineers. Successfully implemented preventive maintenance and condition monitoring systems for all critical to process equipments including reduced breakdown frequency and improved machine availability. Efficiently handled effective conversion of Electric Fired Decorating Lehrs into natural gas fired system. Pivotal in designing natural gas pipeline layout with pressure regulating and safety accessories. Shouldered responsibility of examining all static and rotary equipments so as to ensure zero breakdown and uninterrupted machine availability. Played a major role in executing erection work of Utility Equipments, Annealing Lehrs, Belt Conveyors. Essayed a stellar role in implementing pilot projects to conserve energy and ensure profitable operations.

Key Highlights Instrumental in mentoring and motivating a team of 35 members entailing Engineers and Technicians. Significantly contributed in handling charge of 10 MW Captive Power Plants, 20000 CFM Compressed Air Generation Plant; efficiently carried out maintenance activities, checked for bottlenecks, increased uptime of machines. Pivotal in executing minor and major overhauls (up to 48000 hours overhaul) of Wartsila and Sulzer DG Sets inclusive of Cylinder Head servicing, Fuel Injection Pump & Injectors servicing testing and calibration, Piston and Cylinder Liner dismantling. Administered activities like measurement of clearances, main bearing and connecting rod bearing replacement, crankshaft grinding to fit undersize bearings, ABB turbocharger overhaul, alternator overhaul, Alfa Laval Centrifuge major servicing, etc. Played a major role in handling operations of 4 MW Wartsila DG set for 8250 hours in a year with 95% load factor by adopting detailed planning and executing the preventive maintenance. Efficiently reduced average machinery downtime from 2.5% to 0.4 % within 2 years by identifying system weak spots and implementing predictive maintenance and condition monitoring. Led Utilities Project Team for glass plant capacity expansion from 250 TPD to 600 TPD. Successfully carried out erection & commissioning of the 2x400 KL HFO storage and handling system with Steam Heat Tracing System. Spearheaded Container Glass Screen Printing Unit with 6 Lakhs BPD capacities.