Associate Manager | Vedanta Limited | Aluminium & Oil and Gas | Odisha
Process Optimization
- As the program manager for Business Excellence projects, led multiple sustainability focused Six Sigma initiatives on energy consumption reduction, carbon consumption reduction, and current efficiency improvement. These projects delivered savings of over ₹41.5 Cr by reducing overall cost of production by 12% and specific CO2 emissions by 8%.
- Led cross-functional root cause analysis teams for early-life failures of smelter linings, implementing recommendations based on root causes improving average useful life by 6%
- Conducted value stream mapping and time-work analysis for 12 manufacturing operations, reducing pending work frequency by 75% and employee fatigue by 14%.
Digital Transformation
- Drove the integration of an in-house developed control system project worth INR 12 Cr across smelter lines. Led joint incremental improvement projects to enhance synergy between technology and processes, improving technology fitment.
- Led the development of an AI-powered statistical process control tool for raw material feed frequency, reducing variations in process parameters, improving process efficiency by 1%, and lowering raw material consumption by 5%.
- Collaborated with customers to develop an RFID-based finished goods movement tracker app, reducing variability in arrival times and standardizing wait times across smelter lines. This led to a reduction in average ladle TAT from 49 minutes to 35 minutes and eliminated inventory freezes, which had occurred around three times per month, to zero for the last five years.
- Worked on the smelter’s Digital Twin technology in collaboration with GE to improve preventive maintenance standards and reduce downtime.
Innovation
- Spearheaded the development of capabilities at a local carbon refractory supplier, reducing reliance on Chinese supply chains during a critical production ramp-up at Vedanta Resources in Odisha. Identified bottlenecks caused by supply limitations and successfully implemented process optimizations, ensuring seamless production scale-up.
- Led a 60-crore rupee project to reduce aluminium smelter restart time by implementing a system to move entire pot shells to a separate location. Designed and executed a process akin to single-minute exchange of dies (SMED), allowing for immediate replacement with pre-lined pot shells, significantly cutting downtime and improving operational efficiency.
- Collaborated with Brazilian experts from CEATE to develop a patented pot lining technology for aluminium smelters by integrating copper bars into cathodes to enhance thermal conduction and energy efficiency. This initiative extended smelter life and resulted in annual savings of approximately INR 8 Cr.
Quality Management
- Implemented rigorous quality control frameworks and real-time monitoring systems, reducing chemical variance by 10%. Coordinated Factory Acceptance Tests with third-party inspection agency TUV Nord across 12 countries. These initiatives boosted oil recovery from 20,000 to 23,000 barrels per day and minimized operational waste, delivering ₹41.5 Cr in savings within the first year.
- Was appointed the management representative for ISO 9001:2015 adherence and led all internal compliance audits for asset optimization, quality management systems, and integrated management system for northern Rajasthan oil exploration activities.
- Collaborated with Dorf Kettle to digitalize lab processes and implement FIFO and FEFO inventory systems for chemicals and raw materials. Leveraged AI tools to optimize safety stock levels, resulting in zero stock-out instances for three consecutive months, and introduced an automated stock level warning system for ex-ante inventory control.
People
- As a champion for shop floor safety, initiated and led the organization-wide Project ‘ANZEN’, covering over 5,000 employees. The project increased awareness of safety cardinal rules, unsafe acts, unsafe conditions, and other leading indicators, drawing learnings from past incidents within the group.
- Led the KSA (Knowledge, Skills, Abilities) mapping and training needs identification process for a team of over 100 employees. Ensured alignment with role-specific skill sets and regularly updated training programs to meet evolving operational and industry needs, fostering continuous professional development.
- Spearheaded sustainability awareness drives under the Vedanta Sustainability Assurance Program (VSAP) covering over 1,000 employees across three years, enhancing sustainability culture within the organization. Collaborated with DNV to conduct external compliance audits, achieving improved sustainability scores of 80%, 82%, and 86% for the smelter in 2021, 2022, and 2023. Drove initiatives that focused on environmental stewardship, health and safety, and social responsibility, ensuring adherence to global sustainability standards and contributing to the company’s continuous improvement in sustainability performance.