KPI Optimization: Monitored and improved technical KPIs across 8 cement plants, driving efficiency and reducing costs by identifying deviations and implementing corrective actions.Fuel Management: Analyzed fuel receipts and consumption, optimizing fuel mix usage to lower costs while ensuring compliance with environmental standards. Successfully optimized kiln operations under low-sulfur coal restrictions, achieving significant savings.Energy Efficiency: Executed monthly heat and energy balances, enhancing pyro process efficiency and identifying improvements in waste heat recovery, leading to better overall energy performance.Data-Driven Insights: Leveraged SAP for data extraction and analysis, generating reports that informed strategic decisions on plant performance and fuel management.Teamwork: Facilitated monthly performance meetings with plant managers and operations teams, addressing issues and driving continuous improvements. Collaborated with GMs and department heads on technical KPIs, cost management, and inventory control, resulting in operational enhancements.Coal & Quality Control: Managed monthly coal receipts from local and international sources, ensuring quality control and compliance with offer limits. Conducted cost reconciliation, enhancing budget accuracy by analyzing fuel price per million calories.Project Management: Provided technical support for major projects, improving timelines and outcomes. Streamlined record-keeping for cement and clinker stock across 5 plants, facilitating effective shutdown/startup planning and minimizing costs.Environmental Compliance: Monitored flue gases and particulate matter emissions, ensuring compliance with NOX and CO regulations by resolving exceedance issues in collaboration with the production team.Operational Troubleshooting: Conducted detailed breakdown analysis of kiln equipment, identifying and correcting inefficiencies, improving operational uptime and reducing maintenance costs.

Comprehensive Training: Completed an extensive training program covering the full cement production process, from limestone crushing to packing. Gained hands-on experience in process optimization and equipment troubleshooting across key plant areas.Plant Operations: Managed operations in the feeding area, raw mill, and kiln, ensuring compliance with Standard Operating Procedures (SOPs) to achieve optimal production efficiency. Monitored Waste Heat Recovery Power Plant (WHRPP) and boiler operations, proactively resolving issues to maintain continuous operation.Shutdown and Startup Management: Led and monitored activities during kiln lit-up, cold kiln startup, and feed startup according to SOPs, ensuring smooth transitions and minimal downtime.Energy Efficiency Projects: Contributed to energy savings by addressing false air infiltration and optimizing operations, leading to a reduction in fuel consumption and power usage.Logistics and Inventory Management: Managed coal stock and daily transportation logistics, ensuring consistent fuel supply and minimizing disruptions to plant operations.Collaborative Projects: Worked closely with the production team on the GCT (Gas Conditioning Tower) project, which resulted in energy savings of 0.22 KWH/ton of material, enhancing overall plant energy efficiency.Maintenance and Repair: Actively participated in shutdown activities, assisting in the maintenance and repair of critical equipment, which contributed to reduced downtime and improved operational reliability.

- Completed a 3-month intensive training in Raw Material Handling, Pre-Esterification, Trans Esterification, Distillation, and Recovery areas, gaining proficiency in biofuel production processes- Optimized distillation processes by collaborating with the production team to adjust parameters, resulting in increased production efficiency.- Troubleshot critical equipment, including the vacuum distillation column, RVP, centrifugal pumps, and flow/level measuring instruments, ensuring optimal process performance.- Led a 4-member team in supervising the distillation area, fine-tuning operational parameters, and significantly enhancing overall production efficiency.

Analyzed Boiler, Cooling Tower, and RO plant operations across 14 industries, optimizing chemical dosing to prevent scaling, corrosion, and fouling, which improved system efficiency significantly.