1. Hemendra G Satbhai
E-Mail: hgsatbhai7@gmail.com, Contact No - 8550999207 or 9225103858
Manufacturing Plant Head and a firm believer in safety practices
Key skills - Production & Maintenance  TQM  Supply Chain Management & Vendor Management  Project Management  EHS
AN OVERVIEW
I am a result oriented professional with qualitative experience of >21 years in managing EHS, Production, SCM, Projects, TQM,
Process Enhancements and Team Management. Currently I am responsible for entire plant operations & maintenance which I am
leading with key focus on EHS, top line enhancement with bottom line profitability improvement by ensuring optimal utilization of
resources. Demonstrated abilities in SCM function such as vendor management, techno-commercial negotiations, scheduling, and
procurement of capital goods, spares, materials and services.
I am having good analytical and interpersonal skills, exposure of working with union representatives cordially, proven ability in driving
numerous quality enhancements, improvement initiatives during the career span.
EDUCATION & CREDENTIALS
 Masters In Business Studies (Supply Chain Management) from Pune University
 P.G.D.B.M. (Production & Materials Management) from Pune University
 P.G.D.M.M. (Marketing Management) from Pune University
 Diploma in Metallurgy Engineering from M.S.T.B.E (G.P.Pune) in 1993 with 1
st
Class
 X from SSC Board, N.M.V.High school Pune with 1
st
Class in 1990
AREAS OF EXPERTISE
EHS Management:
 Implementation of Du Pont safety practices framework with focus on employee involvement
 Improving health performance and awareness through health card and wellness at work place initiatives
 Leading legal compliances by implementing Legatrix system successfully in 2013
 Implementation of non-conventional energy solutions, Waste water recycling and changeover of fuel successfully
 Implemented various “management programs” for improving environmental paramemeters consistently
TQM:
 Leading implementation of TBEM practices & framework with focus on employee involvement in the unit.
 5-S & TPM deployment , individual role model demonstration and building improvement culture through various TPM pillars
 Developing and implementing “Policy management” and “Daily Management” process for the unit.
 Certified “Green Belt” and facilitating six sigma, DMAIC and lean projects in the unit.
 Deploying “Theory Of Constraints” principles in unit and doubled top line in 5 years with debottlenecking
Production management
 Planning day-to-day strategies, budgets, manufacturing schedules, along with resource allocation and machine loading for
optimum output.
 Minimizing performance bottlenecks for high productivity by maximizing men, material & machine.
 Appraising the prevalent manufacturing systems/ processes, identifying loopholes if any and undertaking result-oriented measures
for alleviating them and documenting the same.
Maintenance management
 Planning day-to-day strategies, budgets, maintenance schedules, along with resource allocation and machine uptime for optimum
output.
 Directing and guiding team for TPM-PM pillar implementation and focus on 5-W 1 H (Watanabe model) for RC analysis
 Introduced TBM , CBM and continuous review and improvement of the same year on year
 Created focus on “zero failure” equipments through deployment of TPM-PM pillar
 Effective deployment of SAP-PM system
Quality (Supplier & Process)
 Getting Inspection non-conforming products and initiating requests for corrective and preventive action.
 Taking stringent quality measures including preparation of necessary documents like PFMEA, Control Plans to ensure compliance
with above standards & customer requirements.
 Maintaining various quality standards for incoming materials ensuring stringent adherence to quality standards, norms & practices.
Vendor Management
 Actively involved in capital purchases , long term contracts for the unit
 Assessing the performance of the vendors based on various criteria such as percentage for rejections, quality improvement rate,
timely delivery, credit terms, etc.
 Overseeing follow-up with vendors for deliverables, and quality checks & ensuring timely payments.
 Planning, organizing and controlling all requisite activities to perform such as sourcing, techno – commercial evaluation,
negotiation, recommendation, inspection, etc.
Managerial Skills
Excellence in Analysis & Problem Solving
Sound Judgement, Persuasive Communicator
Decision Making Skills
Achievement Oriented Team Builder
Skillful Execution, People engagement
Ethical behaviour
Functional Skills
Production & Manufacturing with safety
EHS & Quality Management Systems
Procurement & Vendor Management
Process Improvement Initiatives
Failure & Root Cause Analysis Management
Critical Chain Project Management

2. Team Management
 Directing, leading & motivating workforce and imparting continuous on job training for accomplishing greater operational
effectiveness/ efficiency. Implemented “Multi-Skilled Operators” Concept successfully
 Working on succession planning of the workforce, shift management activities and appraising the member’s performance &
providing feedback.
Capital Project Management snapshot:
Lead various capital expenditure projects for the business unit in past 5 years enabling capacity and quality enhancement
 Lead conversion of 18 hi reversing cold rolling mill to 4 hi design enhancing its capacity from 0.1 mtpa to 0.25 mtpa
 Lead Batch annealing capacity expansion, Addition of 4 BAF bases for adding capacity of 0.1 mtpa
 Upgradation of existing roll grinders
 Installation of new Hydrogen Generation plant from M/s PERIC - China
 Installation of new 40 tons EOT crane in Annealing bay and 5 mt portal crane at Roll shop
 Pickling revamping taking its capacity from 0.1 mtpa to 0.3 mtpa
 Installation of EDT(Electro-Discharge Texturing ),
 Installation of Electro-static oiler on current Skin Pass Mill for enhanced surface finish of products
 Currently working on Installation of Waste Water Recycling (RO) plant for making unit “Zero Liquid Discharge-ZLD”
 New roll grinder installation with M/s Tenova Pomini
 Extension of Plant shed
TECHNICAL MATRIX
Operational Knowledge
 Sound knowledge of Cold Rolling processes (Pickling , 4 hi mill , BAF , Skin Pass Mill etc) transformed equipment uptime by 25 %
using TPM pillars framework
 Implemented best maintenance practices of TBM and CBM along with condition monitoring methods. Good networking with
supplier OEMs enables fast response during troubleshooting whenever needed
 Project handling, selection of technology , detailed project report , approvals and execution with capital expenditure framework and
guidelines
 Expert in leading “Safety Excellence Journey” using Du pont framework with focus on behavioural safety aspects, firmly believes
that all injuries at work place can be prevented
ORGANISATIONAL SCAN (Present Role)
Since Feb 12 : TATA Steel , Cold Rolling Complex-Tarapur as Head Operations and Maintenance (Plant Head) with additional
responsibility of Projects
Notables:
 Played a pivotal role in maintaining the minimum inventory of finished goods, WIP components & other materials like rework
components , scrap etc.
 Develop AOP for the unit and cost plan including repair maintenance plans , GAGW , spares and product cost budgets and
monitor performance
 Identifying bottlenecks and worked on them to increase throughput through utilisation and uptime improvement by 25 %
 Leading implementation of QMS - ISO/TS-16949, ISO 14001 and OHSAS 18001 through regular management reviews & actions
 Expertise in directing the SGA- circle activities to solve the problems. Competently extended necessary assistance in
implementing Quality Circle, Kaizen (JH pillar) activities.
 Effectively ensured the safety in the plant, PPE compliance. Strive to achieve zero accident (successfully achieved in last 5 years).
Monitoring the safety sub-committees as per Du pont processes.
 Management team size 153 workmen’s, 5 Sr. Managers and 20 Engineers / Asst.Managers
 Coordinated for the control of non-conformity products, equipment failures and took preventive and corrective actions using tools
such as 5W-1H Analysis, Phenomena observations, Fish Bone Diagram.
 Supply Chain Management ushered activities related to demand planning & forecasting for major SKU on the basis of
Sales forecast received from Sales team.
 Managing material flow in such a way that customer SKU level compliances.
 Facilitated the defect monitoring & implementation of Kaizen’s to eliminate defects & sustaining the discipline towards Quality
 Responsible for Liasoning with Factory Inspector , MPCB and MIDC being a “Factory Manager”
Previous roles:
Jul ‘08 – Jan12: Sr Manager Operations & Maintenance (Strip Pickling, 4 hi mill, Roll shop and ETPs)
 Lead up-gradation and project activities as I was specially deputed for execution projects like revamping of reversing cold mill ,
pickling , up-gradation of 2 roll grinders to CNC and mechanical upgrade , Installation of new Effluent Treatment Plant
 Shouldered the responsibility for reviewing Vender’s work progress, quality improvement & elimination of stale activities to reduce
cost & enhance quality, etc.
 Implementation of TOC concepts such as Drum-Buffer-rope (DBR) to support next bottleneck operation
 Implemented TQM-DAILY Management & PSTA system in operations resulting 40% reduction in operations delays
Feb ‘05 – Jun ’08: – Sr Manager – Purchase and Stores
 Lead implementation of SAP-MM & SAP-PS , SAP-CO modules in procurement along with IT team
 Responsible for complete procurement activities for the unit that includes process consumables, MRO and spares, contracting ,
outsourcing , Imports , stores and logistics
 Development of vendors , Vendor performance management
 IT enabled feedback process to user departments on PR status as well as material receipts to improve efficiency. Purchase request
(PR) to Purchase order (PO) lead-time.
• Prioritization based on constraint resource hierarchy and supports them to improve utilization
 IT enabling of bill management system
 Maintaining & Updating Records for Purchase Orders ,Invoices Hard &Soft Copies
 Spares Management and Inventory control using MRP , E-Procurement
 Improved scrap realization by adhering to auction process

3. May ‘02 – Jan-05: Head- Improvements
 Worked as a Task Force member for 1.5 years with Mackenzie Consulting on customer value management CVM , Customer
Product Optimisation CPO with marketing team on full time basis value creation of Rs 9.7 Crs
 Worked as a TOC application expert with M/s Goldratt consulting for 1 year for TOC solutions implementation
 Completed Green belt project thrice under IGE consulting & certified
 Leading Knowledge Management “KM” implementation
Dec ‘01 – Apr-02: Unit Leader – Product QA
 Implemented QS-9000 & TS-16949 as a Asst. Management Representative.
 Handling Customer complaints , CSI actioning
 Implementation of TDC’s (Technical Delivery Conditions) as a plant interface with M&S team
 Implementation of PFD, PFMEA and CP for all manufacturing processes regular review and actions on high RPN items
Feb-96 – Nov-01: Sr. Officer – Production and Maintenance
 Involved in commissioning of skin pass mill , cut to length lines & shot blasting machine
 Working as a shift in-charge for main 18 hi reversing mill and skin pass mill responsible for production and maintenance
 Day to day planning of Skin pass mill and 18 hi reversing mill operations and PM activities.
 Training of operators during initial phases
Feb-94 – Jan-96: Jr. Officer – QA
 Co-ordinating outside processing of CTL products at EPA’s while own machines were under commissioning
 Inspection , testing and certification of products
 Co-ordinating trial supplies to auto companies , trials at annealing and skin pass
 Involved in establishing Laboratory equipments and processes
 Training of operators during initial phases
Other Highlights:
 Worked as a Task Force member for 1.5 years with Mackenzie Consulting on customer value management CVM , Customer
Product Optimisation CPO with marketing team on full time basis value creation of Rs 9.7 Crs
 Worked as a TOC application expert with M/s Goldratt consulting for 1 year for TOC solutions implementation
 Completed Green belt project thrice under IGE consulting
 Implemented TS-16949, OSHAS 18001 & ISO 14001 as a Asst. Management Representative.
 Implementation of Du pont safety systems and trained on Du pont safety practices extensively
 Yield Improvement at customers place (Mahindra & Godrej)
Certification:
 Certified Internal Auditor in ISO/TS-16949-2008
 Certified practitioner TOC – Operations SCM and logistics by Goldratt schools & TOCICO- USA
 Certified Green Belt
 Du pont safety systems, Safety observations , Safety standards , Contractor Safety , PSRM
 Critical Chain Project Management
 TPM instructor
PERSONAL DOSSIER
Date of Birth: 8
th
July 1975
Permanent Address: Flat no 204 , Roop Rajat Nagar , off- boisar – Tarapur road – Boisar , Dist. Thane - 401501
Languages Known: English, Hindi, Marathi
Current CTC - Rs 34.78 Lakh / yr
Expected – Negotiable
Passport available – Yes
I hereby declare that the above-mentioned information is correct to the best of my knowledge and I bear the responsibility for the
correctness of the above-mentioned particulars.
Yours sincerely
Hemendra G Satbhai