AMARESH KUMAR NAYAK
Mobile:971-55-9875507
e-mail: amaresh_41@yahoo.com
Flashpoint
? Experience
Diligent, Dynamic, Resourceful professional, with 26+ years of achievement driven experience in managing end to end Project management & Plant Engineering. Exposer in handling International Projects at Dubai and Nigeria.
? Project Management
Concept to commissioning of Green and Brown Field Projects (Pharmaceutical, Textiles, Steel, Tyres, Hotels & Fabrication Industries.
Gap Analysis and Feasibility study for new and improvement Projects.
Communication Management and Stakeholders involvement.
Quality in Design
? Engineering and Maintenance
Preventive Maintenance Planning, Implementations and records.
Value engineering & conservation of Energy
Break down Maintenance, MTBF & Root Cause Analysis.
Operation Management of Utility (Clean & Black) Systems.
Monitoring, control and cost reduction on utility consumptions.
Critical spare identifications and Management
Records and Reporting
? Quality Management
Planning and Implementations of QMS to meet International Standards like ISO 9001, ISO14000, CGMP, USFDA, MHRA, WHO NAFDAC, TGA requirements.
? Safety Management
Planning, Training and Implementation of Systems and Techniques (6 step procedures) to ensure 100% safety at workplace.
EHS compliance to statutory and regulatory requirements
Zero Tolerance to Unsafe conditions and unsafe acts.
? Cost and Time Management
Budget (Capex and Opex) preparation and control.
Cost reductions with design optimizations and new techniques.
Time Management (MSP, CCPM,TOC etc)
? Resource Management
Exhibits strong leadership skills with focus on results, achievement, striving for participation, involvement and fostering openness and teamwork at all levels. Managing and Motivating the team with guidance and training to achieve organization Goals.
? Decision Making
Strong decision taking capabilities as well as comfort level at taking calculated risk during project management and Plant Engineering.
Professional experiences
High light of Projects Completed
? Green Field Sterile Projects (Injectable facility) for Wockhardt Bio Ag at Dubai
2015-2017
? Green Field projects for Derma products at Visakhapattanam - Dr.Reddys Laboratories Limited-2014
? Green field project for Liquid and Solid Oral Dosage at Nigeria-Ranbaxy Laboratories Limited-2012-13
? Green Field project for Oral Solid Dosage at Baddi –Dr. Reddys Laboratories Limited-2011-12.
? Brown Field project for OSD, at Hyderabad –Dr. Reddys Laboratories Limited-2009-10
? Brown Field projects for Oral Solid Dosage (increased capacity from 3.5 Bn to 7 Bn /Annum) at Hyderabad –Dr. Reddys Laboratories Limited-2007-09
? Green Field Project for API at PUNE –Emcure Pharmaceuticals Limited-2005-06
? Brown Field Project for API at Chennai –Nicholas Pyramal Limited-2004-05
? Brown Field Project for API at Chennai –Sanmar Specialty Chemicals Limited-2000-03.
? Green Field Project for API at Chennai –American Remedies Limited -1997-2000
? Green Field Project for Oral Solid Dosage at Pondicherry –American Remedies Limited.
? Electrical & Mechanical works of MRF Limited (Tyres mfg. company)–Chennai and Arakkonam.
? Textile Industry for Ambattur Clothing Company.
? Electrical works of (Steel Industries-Rolling mill) Sumangal Steel and Soubhagya Steel.
? Complete Electrical works of Hotel-Le-Royal Merridian –Chennai.
? MEP WORKS for Octonarm (I) Ltd
Currently serving Ms. WockHardt Bio Ag ( Joined in July- 2015 as Asst. General Manager-Projects & Engineering.
Project Lifecycle Management: Manage / Plan Infrastructure projects – Green & Brown field projects, scale-up projects of varied products and categories within cost and time with optimum safety and Quality.
Planning & executing a Green Field Sterile (Injectable) project at Dubai. The facility is designed and executed to meet international standards and compliant to USFDA/ EU GMP/ WHO/MHRA regulations.
Safety: Implementation of safety standards and procedures to ensure Zero reportable accident or incident ( “GOAL ZERO “) throughout the life cycle of projects. Ensure 100% implementation of 6 steps CSM (Contractors Safety Management) procedures.
Construction Management: Scheduling, monitoring, reviewing and reporting the life cycle of project for timely completion with optimum safety, quality and within cost.
Communication Management: Involve all stakeholders and clearly state and identify responsibility and mode of communication for each and every participant.
Risk Management: Involve the team in identification, listing, and rating of various risks. Communicate and educate the team and ensure preparedness to handle risks.
Quality by Design: A key component for operational excellence is to build in quality in the design.
Value Engineering: Reduction on capital investment and running cost by design.
Hazop Study: Identifying all the Hazop nodes, review and remedial action for the same in design stage.
Engineering & Maintenance: Preparation & Implementation of QMS documents as per International regulatory requirements.
Operation and Maintenance of all Utilities
Maintenance of Process Equipment and Facilities.
Training and Motivation
Value Engineering and Conservation of Energy
Ms. Dr. Reddys Laboratories Limited ( Joined in April- 2014 as Associate Director-Projects
Project Lifecycle Management: Manage / Plan Infrastructure projects – Green & Brown field projects, scale-up projects of varied products and categories within cost and time with optimum safety and Quality.
Green Field project for Derma products (both potent and General) at visakhapattanam was designed, planned and Executed in a period of 7 months and qualification by 3 months. The facility is designed and executed to meet international standards and compliant to USFDA/ EU GMP/ WHO/MHRA/MCC regulations.
This facility was approved by USFDA in its first inspection without any observations.
Ms. RANBAXY LABORATORIES Ltd ( From July- 2012 to April 2014 as Sr.Manager E&F
Planned and Executed GREENFIELD project for Liquid & Oral Solid Dosage formulations at Nigeria. The facility was designed and executed to meet international standards and compliant to USFDA/ EU GMP/ WHO/NAFDAC regulations.
Complete Design, Planning and Execution of the facility was done by me at Nigeria.
M/s Actavis Pharma Manufacturing Pvt Ltd (global turnover USD 2500 mn)- from JAN- 2012 to July 2012 as Sr.Manager Projects
Responsible for setting up a brown-field expansion project for Oral Solid Dosage formulations for expanding from existing 0.5 Bn capacities to 5 Bn capacities. The facility shall be of international standards and compliant to Actavis Global standards, USFDA/ EU GMP/ WHO regulations.
This Project was dropped basis of top management decisions after Basic and detailed Engineering phase completion.
Dr Reddys Laboratories Ltd (turnover USD 1700 mn)-Joined in Sept 2006 as Dy Manager and relieved in Jan 2012 as Sr.Manager– Formulations TechOps Projects.
My responsibilities constituted of, but were not necessarily limited to:
Project Lifecycle Management: Manage / Plan Infrastructure projects – Greenfield projects, improvement projects, scale-up projects of varied products and categories, with total budgets over US $60 million, as listed below:
• Major Expansions of 100% Export Oriented Unit Oral Solid Dosage Facility from 3.5bn to 7.0bn capacity.
• Green field OSD facility of 3bn capacity at Himachal Pradesh-Baddi
• Ware house capacity enhancement
Project Management based on principles of Earned Value System, Theory of Constraints using MS Projects, Concerto as a Tool.
EMCURE PHARMACEUTICAL LIMITED From Feb 2005 to Sep.2006 as Asst. Manager . Projects & Engineering
Emcure is one of the fastest growing organizations in Pharmaceutical industries expanding both in Formulation and Bulk drug mfg. As Asst. Manager Projects &Engg my responsibility was
• Project Lifecycle Management: Manage / Plan Infrastructure projects – Greenfield projects, improvement projects, scale-up projects of varied products and categories. Completed MEP work of API plant at Kurkumbh –Maharastra without any supports from Consultants. Design, Planning, Supports for SCM for complete Electrical and Mechanical works was independently handled .
• ENGINEERING &MAINTENANCE:-Man power planning, Preventive maintenance planning and implementation, Log book monitoring, History card monitoring and action plan, calibration of instruments, inventory control, Annual Maintenance budget preparation, statutory &compliances, training, Team building and Motivation, conservation of energy,5S implementation, identification of improvement need in existing system and design way forward for continual improvement.
NICHOLAS PYRAMAL LIMITED from Aug 2003 to Feb 2005 as Asst. Manager Electrical &Instrumentation
M/s NICHOLAS PYRAMAL LIMITED is a leading manufacturer of Formulation, APIs and intermediates in India, For a vertical growth in API and intermediate drugs a facility was taken from ICI LIMITED, Chennai and challenge was to complete the project and produce the Drugs from the facility within 10 months.
My job responsibilities and contributions included:
Design:-In house design of complete Electrical and Instrumentation engg package.
Construction management :- Scheduling, monitoring, reviewing and reporting the execution of project with optimum quality and within cost
Documentation &Validation:-. Preparation of all the IQ, OQ, PQ documentation and demonstrate to QA during validation
ENGINEERING &MAINTENANCE:-Man power planning, Preventive maintenance planning and implementation, Log book monitoring, History card monitoring and action plan, documentation for QMS, calibration of instruments, inventory control, Annual Maintenance budget preparation, statutory &compliances, training, Team building and Motivation. Conservation of energy, 5S implementation, identification of improvement need in existing system and design way forward for continual improvement. Implementation of automation and latest technology for better productivity and safety.
PLANT AUTOMATION:-Apart from other partial automation project a complete automated plant for Monosulphurum was architect, designed and executed. Output of 12T/month was achieved without any operators.(Except PLC Operator)
CONSERVATION OF ENERGY &VALUE ENGINEERING:-Various energy saving proposals were implemented and annual saving of 1crore INR was demonstrated.
SANMAR SPECIALITY CHEMICALS LIMITED From Feb.2000 to Aug 2003 as Asst. Manager
M/s Sanmar Specialty Chemicals Limited, an Unit of M/s Chemplast Sanmar., is a API &intermediates unit at Chennai with a clear vision to expand the API business in US and Europe market with low volume and high value products.
My job responsibilities and contributions included:
? Project implementation:-Design and execution of E&I Engg packages for new projects which got USFDA approval.
? Equipment performance trials for process optimization.
Documentation &Validation:-Preparation of all the IQ, OQ, PQ documentation and demonstrate to QA during validation and explained to USFDA auditor during audit.
Participation in Certification of Quality Management System and internal audit of QMS as organizations CERTIFIED INTERNAL AUDITOR.
ENGINEERING &MAINTENANCE:-Maintained the facility with less than 1% breakdown of equipments by proper Preventive maintenance planning and implementation, calibration of instruments and inventory control. Annual Maintenance budget preparation, conservation of energy, statutory &compliances, training, Team building and Motivation were some of my key areas.
AMERICAN REMEDIES LIMITED from Feb 1997 to 2000 as Engineer Electrical &Instrumentation .
As an Electrical & Instrumentation Head for API and OSD manufacturing site at CHENNAI and Pondicherry, constituting 1 API and 2 Dosage form facilities my key responsibilities were:
Manufacturing Support– Monitor and ensure < 1% breakdown of Process equipment and utilities.
Harmonization of Practices– Lead the team of technicians of various locations to freeze best practices.
Regular Engineering Reviews (ELECTRICAL)– Inventory of key spares, revenue budget controls, audit and compliance, team training and skill enhancement etc.
Statutory Compliances:-Comply with IER and ensuring nil defect reports from statutory bodies like CEIG/EI, SEB authorities.
Documentation & Records:-QMS documentations as per International standards.
Resource Management:-Leading a professional motivated team
JANKANS FROM Aug.1993 TO Feb 1997 as PROJECT ENGINEER .
Project Management:-
? Planning, execution, testing and commission of complete electrical &Instrumentation work.
? Preparation of electrical drawings and getting approval from CEIG.
? Arranging Inspection for getting the safety certificate from office of the CEIG.
? Finalization of Electrical contractor for erection, testing & commissioning
? Billing & payment follow up.
? Joint measurement checking & certification of bill.
? Site handover to Clients with necessary documents.
PROJECT EXECUTED FOR THE CLIENTS
MRF LIMITED, EID PARRY(I) LTD, SOWBHAGYA STELL LTD, AMBATTUR CLOTHING COMPANY, MOUNT METTUR PHARMACEUTICALS, LE ROYAL MEREDIAN
ANJANEYA ENGINEERING FROM Sept.1992 TO Aug.1993 as Production supervisor .
? Man and Materials Planning, for fabrication, wiring & testing of LT PANELS
? Preparation of electrical drawings and obtaining client approval.
? Arranging client Inspection and getting their approval.
? Commissioning of Panels at clients site.
? Preparation of quotation, Negotiation with client and order finalization.
Education
Degree in Electrical Engineering Institution of Engineers-Calcutta 1992
Academic Accomplishments
• National Rural Talent Scholarship.
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Professional Accomplishments
• Design, planning, Execution, Commissioning, Documentation as per QMS, Maintenance of Process Industries. Expert in Pharmaceutical Industries.
• Trained on Project Management Principles (PMBOK)
• Certified Internal Auditor for ISO 9001
• Employee of the year award in 2002 in SANMAR GROUP
• Competency supervising License from Govt of Tamil Nadu C-21939
Personal Information
Indian, Male, Married (Date of birth:15th March 1970).
References on request