Nilachal Nayak

Project and Maintenance Professional for Pulp Mill, Metal Industries/Automobile/Smelter/ Power plant/ Utilities, with a growth-oriented Organization.

A result oriented professional with over 18+ years of experience in Planning & Execution, Operations & Maintenance and Installation & Commissioning, Capital Project execution,Budgeting,Maintenance coordination Currently Working with AVTB Pulp Mill, Terrace Bay, Ontario, Canada as “Engineering and Reliability Superintendent” Associated with M/S Birla Copper (Hindalco Industries Limited) MANAGER (Mechanical maintenance, Planning & Utilities) raw material handling system, Smelting Furnace, Converter, Anode furnace, anode caster, scrap melting furnace. Skillful in enhancing systems to bring greater cost efficiency levels & energy/power reductions. Ensuring compliance with quality standards and maintaining all related documents. Preparing SMP, SOP, WI, and Maintenance MPR documents. Demonstrated abilities in working on initiatives, thereby bringing down equipment breakdown & achieving annual cost savings. An effective communicator with excellent relationship, and management skills and strong analytical, problem solving and organizational abilities.

• Adjudged as best employee (outstanding achievement) twice at AVTB Pulp Mill
• Certified Auditor (ISO 9001-14001-18001)
• NEBOSCH certified individual for safety
• Six Sigma Green Belt Holder
• Modified anode furnace liner assembly by providing an external cooling system and casting wheel greasing point unit
• Participated in the Quimpro convention in Mumbai in the Kaizen competition
• Appreciated several times for cost-saving and innovative suggestion measures
• Stood first in National level Quality circle presentation at Hyderabad on “reducing converter blowing time”
• Installed and commissioned water cool hood upon converter successfully ($2Million)
• Modified and lowered Converter tuyer zone to enhance furnace uptime
• Upgrade Scrap melting furnace capacity from 150MT/Day to 200MT/Day with major modification
• Installed in-house designed skip hoist for Scrap Melting Furnace
• Won runners-up appreciation in national level Kaizen competition
• Won excellence award in National level QC presentation at Pune amongst 1328 team
• Won 2nd runners up in CII, AURANGABAD (Regional Level) case study presentation in QC concept
• Won 1st runners up in CII, KOLKATTA (National Level) case study presentation in QC
• Represent Hindalco on Outotec Flash Smelting conference at Finland, Poland

• 07/01/22, Present, AVTB, 21 Mill Road, Terrace Bay, Ontario, Engineering and Reliability Superintendent, Supervise and inspect the installation, modification, and commissioning of mechanical systems at construction sites or in industrial facilities, Analyze dynamics and vibrations of mechanical systems and structures, Coordination for obtaining Certification and compliance of mill-wide elevating devices, Supervise technicians, technologists, and other engineers and review and approve designs, calculations, and cost estimates, Conduct research into the feasibility, design, operation, and performance of mechanisms, components, and systems, Plan and manage projects, and prepare material, cost, and timing estimates, reports, and design specifications for machinery and systems, Design machines, components, tools, fixtures and equipment, Develop maintenance standards, schedules, and programs and provide guidance to industrial maintenance crews, Prepare contract documents and evaluate tenders for industrial construction or maintenance, Planning, Execution, Controls, and commissioning of new improvement projects, Mill-wide major maintenance, short shutdown, major shutdown coordination, Budgeting exercise for mill-wide maintenance and upcoming project activities, Maintenance in charge of Pulp Machine area, Cranes, and elevators, Preparation of Monthly maintenance budget, Overall equipment efficiencies, monthly achievements/highlights of Engineering, Coordinating Mill-wide HVAC troubleshooting activities, Coordinating Mill wide Lubrication selection, consumption plan, procurements, and fluid analysis
• 01/01/19, Present, AVTB, 21 Mill Road, Terrace Bay, Ontario, Engineer, Capital project in charge of ESP for Power Boiler includes Planning, Execution, Controls, commissioning ($8.5Millon), Maintenance in charge of Machine area, Cranes, and elevators includes Daily planning, Execution of short and major shutdown activities, certification and compliance of Elevators, man lifts as per TSSA Norms, Coordination and assistance in Lime Kiln, Steam area Major shutdown activities, Roofing repairs, Structural repairs of Mill, Successfully accomplished Conveyor canopy projects upon Bark system conveyors ($0.45 Million), Successfully accomplished Project of Major Electrical refurbishment of Wet End crane of Machine area ($0.6Million), Successfully planned, and coordinated the East White Liquor clarifier’s 30’ shell replacement along with internal rake modification ($2.2Million), Upgradation of Freight Elevator ($0.5Million), Streamlined Machine roll maintenance schedule and upkeeping of rolls, Upgraded the Pulp Mill Stretcher mechanism at the machine
• 02/01/05, Present, Hindalco Industries Limited (Birla Copper), Manager (Mechanical Maintenance & Utilities), Worked as Maintenance Mechanical in-charge smelting furnace, converting furnace, anode furnace anode casting, scrap melting furnace, west heat recovery boilers and all its related utilities, Hydraulic Circuit maintenance, Cooling Towers maintenance, EOT cranes, Compressors, Blowers, Successfully planned executed and completed the capital repair shutdown, Coordination for preventive maintenance, scheduling, condition monitoring of equipment, and maintaining the availability of equipment for production, Capex and modification in the system and planning for the capital shutdown
• 02/05, Present, Hindalco Industries Limited (Birla Copper), Graduate Engineer Trainee, Erection & Commissioning of plant and process equipment to ensure the completion of projects within stipulated time/ cost parameters using MS-Projects as core tools, Handling project activities for initial start-up & expansion, Responsible for initial load trial run, Hot commissioning & Stabilizing operation of various equipment like Furnaces, pumps, blowers, chain conveyors, belt conveyors, Verification of commissioning documents for Cu- Smelting plant mechanical equipment, Troubleshooting and other technical assistance during major expansion projects for doubling the smelter – I and 2 plant capacity
• 08/06, Present, Hindalco Industries Limited (Birla Copper), Engineer, Maintenance of Anode furnace, Anode caster equipment, Hydraulic equipment overhauling, Rectifying Material handling system, to ensure trouble-free operation and zero downtime, Waste heat recovery boilers – Maintenance, thickness mapping, heat treatment of tube panels before erection
• 09/09, Present, Hindalco Industries Limited (Birla Copper), Sr.Engineer, Had successfully carried out major overhauling jobs of Smelting and waste heat recovery boiler, O/h of Turbo blower, EOT cranes, and Chain conveyors during Plant bi-annual shutdown within budgeted cost and time effective man & material planning
• 07/10, Present, Hindalco Industries Limited (Birla Copper), Asst. Manager, Working as section head, Presently leading a team of 1 assistant manager,3 Engineer & 8 technicians to cater the Department’s targets, Up gradation of Major equipment like rotating furnace, EOT crane, Caster hydraulic system, Overhauling of Centrifugal blower and reciprocating compressor, Spares, Inventory & cost management, Training of subordinates
• 07/12, Present, Hindalco Industries Limited (Birla Copper), Deputy Manager, Working as section head, new project coordinator, Erection and commissioning of Water cool Hood upon Converter, Enhance casting rate, Erection and commissioning of Water cleaning systems for Anodes
• 07/15, Present, Hindalco Industries Limited (Birla Copper), Manager, Working as section head, new project coordinator, Planning/Training/QC/Kaizen, Strategically, plan, analyze & conceptualize the basic requirements while setting up the technical infrastructure of the unit with cost efficiency, time management & manpower planning for the execution, Accountable for implementing Corrective and preventive actions and maintenance of the casting section, Develop validation protocols, validation of products & production scale technologies. Oversee production-related tasks including planning, control, and maintenance & troubleshooting, Provide shop-floor operational support for product transfer, ranging from development to manufacturing products & process optimization and key studies, Develop a detailed checklist leading to a Technology Transfer document for each product transferred to the manufacturing plants while ensuring all pre-execution activities are carried out for Site variations & in-house developed products in line with the respective SOPs, Establish quality standards for setting up & meeting the production targets within time & cost parameters. Skillfully perform all functional tasks, including planning, control & troubleshooting, and solving all breakdowns. Follow up with the supplier for Corrective and preventive action, Instrumental in quality assurance & maintaining quality reports, taking corrective actions for quality-related problems. Develop new process concepts for production optimization, and yield improvement, and develop guidelines for the sequencing of manufacturing activities on the shop floor, Strategically plan the sourcing of raw materials & their estimation. Assess and intimate the requirement of stores for each work well in advance for procurement action by higher authorities. Keep stock of materials to the minimum of requirement and within prescribed limits, Manage a team while providing technical guidance to them on various processing, Monitor regular production, troubleshooting & inventory control management while planning & conceptualizing strategies for the accomplishment of production targets within a specified time & quality parameters, Up gradation of scrap melting furnace from 150 MT/Day capacity to 200 MT capacity/Day, Shut down planner and coordination, Modification of converter Tuyer zone to enhance furnace uptime, Establishment of Water cool hood Upon Converters