Vasu Mahatma

Results-driven professional with prowess in optimizing processes, enhancing efficiency, reducing costs, and problem-solving via technical inputs, data analytics, and Lean Six Sigma. Adept at strategy, operations, project management, and digital transformation.

Quick Look

Work Experience: 6.7 Years

Previous Roles :

Area Manager, Tata Steel Limited

Function : Engineering & Maintainence,Operations/Logistics/Supply Chain,Project/Program Management,Strategy

Industry/Sector: Manufacturing & Engineering

Work Experience

Tata Steel Ltd. | Area manager, Operation & Strategy, Digital Transformation, Project Management | Jamshedpur

Responsible for making strategic interventions, facilitating manufacturing excellence, driving cross functional projects, and managing end-to-end maintenance operations for a ₹9,000 crore annual revenue manufacturing unit, while leading a 70-member team

• Led the implementation of a Centralized Digital Command Centre, fostering cross-functional collaboration and driving digital transformation across departments. This initiative reduced plant unplanned stoppage and achieved ₹7 crore in cost avoidance.
• Spearheaded 15+ cross-functional projects to optimize processes, enhance throughput, and unlock productivity, leveraging Data Analytics, Lean Six Sigma to solve complex problems, resulting in a 20% YoY reduction in equipment breakdowns
• Strategized and executed five major planned shutdowns (10-15 days), liaising with internal and external stakeholders to complete 2,500+ critical maintenance and upgradation jobs while effectively managing budgets, resources, and timelines
• Developed 20+ equipment failure predictive models (AI/ML), enhancing operational reliability and achieving ₹2 crore in cost avoidance
• Orchestrated multiple equipment upgrade projects from order placement to deployment and performance guarantee, collaborating with internal stakeholders and multinational OEMs to ensure timely delivery, managing a capex of ₹20 crore
• Secured leadership buy-in and project funding by presenting a strong business case; collaborated with a vendor to digitalize the Store Management System, reducing workforce dependency and cutting spare retrieval time by 50%
• Developed a forward-looking strategy for spare and budget management by optimizing inventory and procurement, creating annual-rated contracts, refurbishing spares, sourcing local OEMs, and implementing a Spare-Sharing System, resulting in cost avoidance of ₹50 lakhs
• Conducted detailed troubleshooting using Root Cause Failure Analysis (RCFA) to resolve a recurring high-speed strip breakage issue, unlocking system capacity, improving yield and achieving ₹1.2 crore cost avoidance
• Optimized maintenance practices by using SAP, data analytics, and Total Quality Management (TQM), updating 50+ SOPs & documents
• Successfully managed multiple quality and process audits, achieving zero major non-conformities and 100% quality standards compliance

 

Tata Steel Ltd. | Manager, Maintenance ,Digital transformation, Project Management | Kalinganagar and Jamshedpur

Responsible for managing maintenance operations, driving improvement projects and digital transformation initiatives to unlock capacity for an area of ₹10,500 crore annual revenue continuous production unit, while leading a 20-member team to achieve operational reliability.

• Led the Industry 4.0 implementation project, co-working with McKinsey & Co. to develop strategies, models, and dashboards, ensuring seamless execution, contributing to the plant’s recognition as India’s first Manufacturing Lighthouse by the World Economic Forum
• Spearheaded safe plant operations during COVID-19 with 50% manpower, implementing innovative solutions to overcome restrictions and optimize resource allocation, ensuring continuous operations and generating ₹1,500 crore in quarterly revenue
• Deployed 10+ regression models for reliability improvement, avoiding cost of ₹1.5 crore annually and reducing plant downtime by 20%
• Managed crisis and resolved a critical equipment breakdown during OEM unavailability, preventing ~4 hours of plant downtime
• Reduced OEM dependency by addressing skill gaps through on-the-job trainings, capability building workshops, and fostering a continuous learning culture, achieving a 30% reduction in Mean Time to Repair (MTTR) and ₹20 lakh in cost avoidance
• Conducted a comprehensive instrumentation analysis of blast furnace, eliminating seven recurring failures and avoiding cost of ₹10 lakhs
• Achieved the department’s first zero-delay month by implementing Quality Control (QC) Circle, a TQM tool, resolving abnormalities, and creating Failure Mode and Effect Analysis (FMEA) documentation and inspection checklists
• Established the department's first incident-free zone and led multiple safety campaigns, driving a 25% YoY reduction in incidents

Accomplishments

• TVS Ride Case competition Finalist Oct-2024

Developed Strategy and designed an end-to-end process for building a competitive intelligence task force for TVS Motor Company

• Awarded Sponsor level Award                                                                    

Recognized by Division Vice President for achieving business goals of delay reduction (plant stoppage) leading to savings of ₹7 crore.

• Awarded Champion level Aspire Award                                                     

Recognized by Division Maintenance Chief for contributing toward Aspire project leading to a savings of ₹2 crore

• Appreciated by VP TSK for managing plant during pandemic               

Appreciated by Vice President, TSK for sustaining safe plant operations with only 20% of manpower and resources during Covid-19 pandemic. 

Education

Bachelor of Technology, Instrumentation and Control Engineering, NIT Trichy 

Certificates

• Supply Chain Fundamentals, Udemy

Course on the Supply Chain concepts and applications

• Excel Skills for Business, Macquarie University, Coursera 

Course on Microsoft Excel skills required for business

• Lean Six Sigma Green Belt, KPMG

Course on lean six sigma methologies, a praticitioner level certification.

• Data Analytics and Visualization, University of Buffalo 

Course on basics of data analytics and visualization.

• Total Quality Management (TQM) for Managers by SumTotal 

Course on TQM comprising various modules such as Daily Management, Various Quality Control tools, total productive maintenance etc.

• Digital Foundations by SumTotal

Foundational course on digital technologies like IOT, digital mobility, crypto currency digital cloud etc.

• Safety Standards by Sum Total 

Course on various safety standards like Working in electrical rooms, Fire Safety Management, temporary electrical wiring, maintenance of earthing systems, Positive isolation, slip trip fall prevention etc.

• Enterprise Risk Management by Sum Total

Course on Risk Management at Enterprise level

 

Co/Extra-curricular

• Completed 11800 ft. trekking to Siyari Top in Uttarakhand
• Completed a Half Marathon organized by Tata Steel Ltd. to promote sustainability awareness.
• Captained the team to victory in the basketball match at Xuberance'24, IIMA's Sports and Cultural Event 
• Regular Blood doner - was a part of NSS (National Service Scheme) in NIT Trichy, organized various health checkup and blood donation camps in NIT Trichy and Tata Steel Ltd.
• Held position of President of AAYAM, the Hindi Cell of NIT Tiruchirappalli - Led a team of 30 members, published magazine, organized various events and activities to promote Hindi 
• Held various Position of responsibilities in NIT Trichy college fests - Executive Head in NITTFEST (intra college cultural fest), Deputy Manager in FESTEMBER (National level cultural fest organized by NIT Trichy)