A. SHUNMUGANATHAN
Mobile: +919629669039 / +233243009738.
E-Mail: shunmuganathan69@gmail.com, Shunmuganathan69@yahoo.com
Seeking assignments in Project Management, Maintenance Operations and Production Management with leading organisation of repute in Poultry feed, Poultry processing, Food & Beverages, Steel, Sugar or Cement Industry.
PROFILE SUMMARY
• Performance Driven Professional with nearly 25 years of experience in Project Management, Operations & Maintenance, Installation & Commissioning, Quality Management, System Management (ISO) and Team Management
• Exposures in all machineries like Bucket Elevators , Conveyors( Belt ,Chain & Screw) ,Rotary feeders ,Blowers , Dryers , Centrifuges , Ball mill , Kilns , Dust collectors ,Air classifiers ,Hammer mills , Mixers , Steam conditioners , Pellet mills , Coolers , Crumbles’ , Different types of Sieves , bagging Machines and Auto loaders . Accessories likes Boilers , EOT cranes , Forklifts , Gen sets , Cooling towers , Pumps and Compressors .
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• Demonstrated excellence in supervising plant projects, with respect to Cost, Resource Deployment, Time Over-Runs & Quality Compliance; evaluating the project progress and taking adequate corrective actions
• Proven abilities in spearheading all the required Graphics / Logic Designing as well as Installation & Commissioning of various equipments along with ensuring the on-time deliveries
• Resourceful in planning, engineering, managing and executing various projects including installation, operations and maintenance of the systems
• Proficient in managing overall project while ensuring high quality standards and meeting KPIs
• Excellent communication & organisation building capability with strong planning & resource optimization abilities
CORE COMPETENCIES
Project Planning & Management Sales Coordination Operations & Maintenance
Industrial & Lean Manufacturing Installation & Commissioning Production Operations
Supply Chain Management HSE Operations Team Management
TPM / Kaizen Poultry farming management
Least cost feed formulation for poultry and aqua feed
Poultry feed milling and Poultry processing plant project execution and maintenance handling.
ORGANISATIONAL EXPERIENCE
Sep’15 – Till date with ABZ Klags International Limited ,Kumasi , Ghana as General Manager for Poultry and Feed (Operations, Maintenance & Projects) Unit of Triton Group .
Key Result Areas:
To head the poultry operations to maintain entire unit system ready,. To overseeing the bio safety and up keep of hygiene and sanitation, To ensure regular up keep off plant, optimized cost, reduce wastages and ensure high productivity & manage people
Overall - Emphasis on sales and marketing activities to gain new customers and to enhance the market position of the company in Ghana
Maintain and strengthen business relationship with existing customers. Identify new potentials based on certain pre-identified parameters.
Assessment of local market requirements in connection with company's range of products and specifications/problem solutions which could be successfully applied with the customers .
Planning of sales and cost targets. Determine conclusions and prepare activities to ensure yearly targets
Steering of sales and marketing communication activities in co-operation with the central unit of company and in line with allocated budgets
Achieve and maintain defined customer service standards and maintain/improve sales processes
Motivate, Train and Assist subordinate and harmonize it with the expectation of the company. Guide and control field forces through Regional Manager to achieve sales budget for every year.
Developing dealers management and ensuring effective distribution and keeps up satisfaction of the dealers and farmers through our best services.
Sep’13 – Sep’15 with Globus resources Limited , Logos , Nigeria as Assistant General Manager for Feed and Processing (Operations, Maintenance & Projects) , Unit of Triton group .
Key Result Areas:
• Planning and effecting predictive & preventive maintenance schedules for various equipments to increase machine up time & equipment reliability
• Implementing maintenance schedules and carrying out periodic checks to ensure performance of various equipments and maintaining requisite documents for the same
• Proactively identifying areas of obstruction / breakdowns and taking steps to rectify the equipments through application of troubleshooting tools
• Carrying out overhauling work of equipments, modifications and major repairs to improve the efficiency of the equipment by faultfinding
• Taking stringent quality measures including preparation of necessary documents to ensure compliance with quality standards & customer requirements
• Managing overall operations for executing projects within cost & time norms; participating in project review meetings for evaluating project progress & de-bottlenecking
• Preparing project schedules and monitoring projects with respect to cost, resource deployment, time over-runs and quality compliance to ensure timely execution of projects
• Handling the complete range of activities by providing right of way from conceptualisation to installation, testing, maintenance and troubleshooting of the equipments
• Inspecting field sites to observe and evaluate condition and operability of facilities/ structures and collecting the field survey data & measurements
• Designing and implementing stringent systems and quality plans / manuals to ensure high quality standards during all the stages of project
• Responsible for materials planning & developing vendors for obtaining timely procurement of materials & equipment at cost effective prices to ensure smooth execution of projects
• Ensuring suitable deployment of manpower & timely availability of manpower
Highlights:
• Contributed significantly towards spearheading various operations such as Planning, Quality Control, Industrial and Lean Manufacturing, Production Administration, System Management and Logistics Operations
• Played a major role in increasing the boiler efficiency from 59 to 69% and upgrade the fuel to steam ratio from 1: 3.5 to 1: 4.1 at M/S Suguna Foods Ltd
• Facilitated the following projects at G.Das & Company Ltd.:
o Reduction of unloading manpower by providing Vibro feeder (24 manpower/day reduced) by introducing bin mill in operation and upgrade the plant productivity to 9% more
o Minimise the industrial grade salt hardness by providing additional cyclone and vibro washing .
• In Hitech Flyash limited – The plant flow diagram designed & commissioned the plant.
• In Suguna
- Designed and established the wear elimination system in material handling ducts
- Increased the hammer mill productivity by introducing the 52% opening sieve which leads 12 % increase in production and reduced the power cost by 12%
- Increased the product quality by avoiding the roasting of the material during grinding .
- Increase the cooler efficiency by providing the insulation and to increase the productivity of 6%
- Reduced manpower in baggi ng section by introducing telescopic conveyor and Rs 32 /ton was reduced
- Increased the sales volume from 1800 tons/month of feed to 4500 tons/month
• At Suguna attained cost savings by providing the additional steam injection during condition that was lead better pellet ability which brought the reduction of rejection rate from 2% to 0.1%
• At Suguna, the cyclone capacity was upgraded and eliminated the dust emission in system which has led to 0.1 % increase in yield.
• Increased the gelatinisation of feed stuff by the additional steam injection during conditioning which was lead to avoid the pellet binder in formulation
Feb’12 – Sep’13 with M/S Amrit feeds Limited ., Coimbatore, Tami Nadu as Senior Manager (Feed Production & Projects)
Highlights:
• Shouldered the responsibility of leading the Operations Functions of the Manufacturing Plant & was responsible for Plant Operations like Production, Quality, Manufacturing, Maintenance, Supply Chain Management, Finance, HR, HSE, etc.
• Effectively provided high emphasis to the Shop Floor to identify & eliminate problems on continuous basis and focusing on the Lean Manufacturing Practices
• Responsible for delivering the Annual Operating Plan and ensuring both local & export (as per status) customer demands are met in terms of quality & delivery
• Efficaciously worked for the installation & commissioning of additional capacity and Legal & Statutory Compliance under various Labour Laws
Aug’06– Feb’12 with Suguna Poultry Farm Ltd., Coimbatore, Tami Nadu as Senior Manager (Production & Projects)
Highlights:
• Proficiently handled the aggregation of EMS & increased the plant capacity from 600 to 1000 Tonnes per day without stopping the plant functions
• Accountable for managing all the Maintenance Operations in the Poultry Feed Mill with the capacity of 1000 MT / day
• Served as the In-charge for the Boiler House and Coordinator for ISO 9001, 14001 & 18001 Implementation
• Bagged with the Kaizen Award for Boiler Operating Cost Reduction & converting the waste into value added products
• Contributed significantly in the Plant Expansion Team for managing the capacity of 600MT to 1000 MT /day
• Distinguished efforts towards implementing the Safety Activity and QCD
PREVIOUS EXPERIENCE
Jul’01–Aug’06 with HI-Tech Fly Ash India Pvt. Ltd., Tuticorin, Tamil Nadu as Works Manager
Highlight:
• Efficiently designed and established Fly Ash Segregation Plant independently In Tuticorin Thermal power plant .
Oct‘95 – Jul’01 with G. Das & Company Ltd., Unit, Kothari Agro Foods Ltd.,Tuticorin , Tamil Nadu as:
Growth Path:
Shift In-charge Oct’95 – Jan’00
Maintenance In charge Jan’00 – Jul’01
Aug‘90 – Oct’95 with Arudra Engineers (P) Ltd., Chennai as Shift Engineer
EDUCATION
• Diploma in Industrial Safety from Annamalai University, Annamalai Nagar First Division with 60% marks in 1996
• BE in Mechanical Engineering from A.K. College of Engineering, Srivilliputtur; secured First Division with 68.2% marks in 1990
ACADEMIC PROJECT HANDLED
1990 Project on Digital Control of Machines
MEMBERSHIP
1995 Life Member in Loss Prevention Association of India Ltd., Chennai
TRAININGS / CERTIFICATION ATTENDED
2007 Management Development Program in Kongu Engineering College, Perundurai
2008 Financial Skills for Non-financial Managers
2006 First Class Boiler Attendant, Certificate of Competency Holder as per the Indian Boiler Act 1923
IT SKILLS
• Proficient in MS Office & Internet Applications
PERSONAL DETAILS
Date of Birth : 25th May, 1969
Residential Address : 2H/47, Kathirvel Nagar - West, 1st Street, Tuticorin – 628008, Tamil Nadu
Languages Known : Tamil & English
Career Professional Track
List of 5 key Green Field projects handled by me .
1, Reverse Osmosis Plant Erection & Commissioning
Company – M/S G.das & Company Limited ,Unit of Kothari Agro food
Location - Tuticorin
Period – 1997 – 1998 .
Role – Responsible for receipt of the materials , Erection and Commissioning .
Capacity – 6000 liters per hour
Project Cost – 75 lakhs
2, Activated Carbon Plant Erection & Commissioning .
Company – Adsorbent Carbon Limited
Location - Tuticorin
Period – 2002 – 2003 .
Role – To assist the Consultant towards the material Handling and process equipments selection and Responsible for the Erection and Commissioning .
Capacity – 2 kilns of 2.5 tons per day
Project Cost – 2.5 core
3, Cement Substitute (Fly ash ) Processing Plant .
Company – HI-Tech Fly ash India private Limited .
Location - Tuticorin
Period – 2004 – 2006 .
Role – To assist the Consultant towards the designing of the plant .
-Efficiently handled the erection & Commissioning of the Fly Ash Segregation Plant independently• Designing and implementing stringent systems and quality plans / manuals to ensure high quality standards during all the stages of project
• Responsible for materials planning & developing vendors for obtaining timely procurement of materials & equipment at cost effective prices to ensure smooth execution of projects
• Ensuring suitable deployment of manpower & timely availability of manpower
Capacity – 250 tons per day
Project Cost – 9 cores
4, Animal Feed plant ( Pellet feed- Poultry) .
Company – M/S Amrit Feeds Limited .
Location – Coimbatore - Nachipalayam
Period – 2012 – 2013 .
Role – To assist the Consultant towards the designing of the plant .
-Efficiently worked for the installation & commissioning of the plant and Legal & Statutory Compliance under various Labour Laws
-Shouldered the responsibility of leading the Operations Functions of the Manufacturing Plant & was responsible for Plant Operations like Production, Quality, Manufacturing, Maintenance, Supply Chain Management, Finance, HR, HSE, etc.
• Effectively provided high emphasis to the Shop Floor to identify & eliminate problems on continuous basis.
-Responsible for materials planning & developing vendors for obtaining timely procurement of materials & equipment at cost effective prices to ensure smooth execution of projects
Capacity – 20 tons per Hour
Project Cost – 24 cores
5, Animal Feed plant ( Mash feed- Poultry) .
Company – M/S Globus Resources Limited .
Location – IWO – Osun State , Nigeria
Period – 2014 – 2015 .
Role – To assist the Consultant towards the designing of the plant .
-Efficiently worked for the installation & commissioning
-Shouldered the responsibility of leading the Operations Functions .
- Effectively provided high emphasis to the Shop Floor to identify & eliminate problems on continuous basis.
-Responsible for materials planning & developing vendors for obtaining timely procurement of materials & equipment at cost effective prices to ensure smooth execution of projects
Capacity – 2 tons per Hour
Project Cost – 6 million Naira
List 0f 5 key Brown Field projects handled by me.
1, Up gradation of Material Handling system in Raw material handling
Company – M/S G.das & Company Limited ,Unit of Kothari Agro food
Location - Tuticorin
Period – 1998
Role – Responsible for receipt of the materials , Erection and Commissioning .
Capacity – 25 tons per hour
Project Cost – 60 lakhs
o Benifits - Reduction of unloading manpower by providing Vibro feeder (24 manpower/day reduced) by introducing bin mill in operation and upgrade the plant productivity to 9% more
2, Production & Quality optimization
Company – M/S G.das & Company Limited ,Unit of Kothari Agro food
Location - Tuticorin
Period – 1998
Role – To design the process flow To develop the detailed and working drawing To execute the erection and commissioning.
Capacity – 5 tons per hour
Project Cost – 90 lakhs
o Benifits - Minimise the industrial grade salt hardness by providing additional cyclone and vibro washing
3, Up gradation of Production in Animal Feed plant ( Pellet feed- Poultry) from 600 tons to 1000 tons per day
Company – M/S Suguna Food limited .
Location – Coimbatore – Udumalpet - Varadharajapuram
Period – 2007 – 2008 .
Role – To assist the Consultant towards the designing of the plant .
-Efficiently worked for the installation & commissioning of the plant and Legal & Statutory Compliance under various Labour Laws
-Shouldered the responsibility of leading the Operations Functions of the Manufacturing Plant & was responsible for Plant Operations like Production, Quality, Manufacturing, Maintenance, Supply Chain Management, Finance, HR, HSE, etc.
• Effectively provided high emphasis to the Shop Floor to identify & eliminate problems on continuous basis.
-Responsible for materials planning & developing vendors for obtaining timely procurement of materials & equipment at cost effective prices to ensure smooth execution of projects
- Proficiently handled the aggregation of EMS & increased the plant capacity from 600 to 1000 Tonnes per day without stopping the plant functions
- Accountable for managing all the Maintenance Operations in the Poultry Feed Mill with the capacity of 1000 MT / day
Capacity – 45 tons per Hour
Project Cost – 18 cores
4, Up gradation of Mash Feed plant to Pellet feed for Poultry and Cattle - 10 tons per day
Company – M/S Suguna Food limited .
Location – Coimbatore – Udumalpet - Ganapathypalayam
Period – 2011– 2012 .
Role – To assist the Consultant towards the designing of the plant .
-Efficiently worked for the installation & commissioning of the plant and Legal & Statutory Compliance under various Labour Laws
-Shouldered the responsibility of leading the Operations Functions of the Manufacturing Plant & was responsible for Plant Operations like Production, Quality, Manufacturing, Maintenance, Supply Chain Management, Finance, HR, HSE, etc.
• Effectively provided high emphasis to the Shop Floor to identify & eliminate problems on continuous basis.
-Responsible for materials planning & developing vendors for obtaining timely procurement of materials & equipment at cost effective prices to ensure smooth execution of projects
Capacity – 10 tons per Hour
Project Cost – 16 cores
5, Broiler farming with Feed mill and Manual Processing .
Company – M/S ABZ Klags International Limited .
Location – Kumasi – Ashanthi State , Ghana
Period – 2015 – 2016 .
Role – To head the poultry operations to maintain entire unit system ready,. To overseeing the bio safety and up keep of hygiene and sanitation, To ensure regular up keep off plant, optimized cost reduce wastage and ensure high productivity & manage people
Overall - Emphasis on sales and marketing activities to gain new customers and to enhance the market position of the company in Ghana
Capacity – Feed mill 2 tons per Hour
Broiler farm – 4000 birds per week
Manual Processing – 500 birds per
Project cost – 100000 USD.
List of my key achievements in Production Operations.
• Contributed significantly towards spearheading various operations such as Planning, Quality Control, Industrial and Lean Manufacturing, Production Administration, System Management and Logistics Operations
• Facilitated the following projects at G.Das & Company Ltd.:
o Reduction of unloading manpower by providing Vibro feeder (24 manpower/day reduced) by introducing bin mill in operation and upgrade the plant productivity to 9% more
o Minimise the industrial grade salt hardness by providing additional cyclone and vibro washing .
• In Hitech Flyash limited – The plant flow diagram designed & commissioned the plant.
•
• In Suguna
•
• Played a major role in increasing the boiler efficiency from 59 to 69% and upgrade the fuel to steam ratio from 1: 3.5 to 1: 4.1 at M/S Suguna Foods Ltd
•
- Designed and established the wear elimination system in material handling ducts
- Increased the hammer mill productivity by introducing the 52% opening sieve which leads 12 % increase in production and reduced the power cost by 12%
- Increased the product quality by avoiding the roasting of the material during grinding .
- Increase the cooler efficiency by providing the insulation and to increase the productivity of 6%
- Reduced manpower in bagging section by introducing telescopic conveyor and Rs 32 /ton was reduced
- Increased the sales volume from 1800 tons/month of feed to 4500 tons/month
• At Suguna attained cost savings by providing the additional steam injection during condition that was lead better pellet ability which brought the reduction of rejection rate from 2% to 0.1%
• At Suguna, the cyclone capacity was upgraded and eliminated the dust emission in system which has led to 0.1 % increase in yield.
• Increased the gelatinisation of feed stuff by the additional steam injection during conditioning which was lead to avoid the pellet binder in formulation