SANJAY JAIN

Mobile: +91-9540457920 ~ E-Mail: sanju2705@yahoo.com

Seeking top level positions in Operations / Production / Quality Assurance / New Business Development with an
organization of high repute in Heavy Fabrication Manufacturing industry.

Profile Snapshot

 Offering above 22 years of experience in Heavy Engineering Fabrication, Production, Planning, Procurement, New
Business Development.
 A keen performer with experience in managing production operations with key focus on ensuring optimal utilization
of resources.
 Having a sharp eye on cost cutting and acumen of business.
 Expertise in reducing rework levels, anticipating problems and finding optimum solutions, inventory management,
vendor development, Technical training,
 Abilities in enhancing production process operations, optimizing resource & capacity utilization, escalating
productivity & operational efficiencies while curtailing costs & expenses.
 Possesses excellent communication, analytical and planning skills with abilities in leading and training team
members.

Skill Set

Production Management: Handling production related tasks i.e., controlling & troubleshooting for achieving the
planned periodic schedules and process control. Minimizing performance bottlenecks for high productivity by
maximizing efficiencies of men, materials and machines, etc. Coordinating with the other departments for
accomplishing production as per organizational guidelines. Conceptualizing and implementing the newer and more
productive methods. Special emphasis on identification of rework areas and their elimination. Monitoring and
managing manpower (Technicians and supervisors) to align the quality and delivery of products.

Quality Assurance: Ensuring adherence to the quality standards and requirements by Clients’; undertaking root
cause analysis of problems and developing effective counter measures. Appraising the prevalent production systems/
processes, identifying gaps, if any, and undertaking result-oriented measures for alleviating them and documenting
the same.

Procurement: Formulating and implementing the procurement strategy by developing / modifying strategy for
purchase and establishing methods to achieve project targets. Planning, organizing and controlling all requisite
activities to perform such as sourcing, techno – commercial evaluation, negotiation, recommendation, ordering,
inspection, expediting & tracking, logistics and delivery, payment processing, etc.

Business acumen: Capex, Opex, Capacity estimations, working capital, Profits and Loss with the projects.

Training: Emphasis on training and knowledge dissemination on practical aspects of Fabrication.

Employment Details

April’17 – Present: Essar Steel India Ltd., Hazira, Surat, Gujarat

Head Fabrication (Unit Head)

Key result Areas

 Heading the complete operations of Essar Steel, Hazira fabrication unit.
 Handling all the departments i.e. Production, Planning, Procurement, Quality, Maintenance, Logistics, Safety, HR,
Marketing.
 Estimations of Costing and pricing for the enquiries.
 Handling a turnover of Rs. 175 Crores with a team of 450 Staff and contractual labours.
 Capacity estimation and preparation of departmental budgets and CAPEX
 Framing and assuring compliance to the requirements including pertinent policies, procedures, work instructions,
and other related process control documents.
 Coordination with Clients/Vendors for external and F&A departments for Internal.
 Working on SAP (ERP system) execution
 Establishing the systems/ SOPs for all the activities into the fabrication perimeter
 Continuous review and improvements in procedures and methodologies.
 Monitoring and managing manpower (Technicians and supervisors) to align the quality and delivery of products.
 Defines and communicates work assignments to shop personnel. Monitors progress of work and address issues as
needed (e.g. re-allocation of resources, alternate sequencing of jobs, resolution of operational/ technical issues).
 Assists in identifying, investigating and resolving equipment/ tooling/ process issues.
 Implementation of 5S
 Monitors and takes action to eliminate waste and drive down manufacturing costs. Assures effective and efficient
utilization of personnel and equipment (ex. Reduction of set-up and cycle times, etc.)
 Monitors KPIs and drives the analysis and identification of opportunities for improvement.
 Settling technical disputes/clarifications during execution of project.
 Contributes towards unit cleanliness and development of cleaning routines.
 Delivers performance reviews, counselling / discipline, and wage increase recommendations.
 Negotiation and awarding orders to Sub- contractors, monitoring the progress and addressing the quality issues.
 Vendor and supplier identification, audit, approval and monitoring.
 Provides inputs to Estimation, Proposal and Marketing departments for the enquiries, technical and commercial
point of view. Handling enquiries from Clients’ for techno- commercial aspects.
 Communicates effectively to management and other departments regarding order status and production issues.
 To conduct audits to ensure adherence to quality and safety norms, designated as trained internal auditor.
 Train and monitor the employees (Production, Welding) engaged in the production process.
 Products being handled are Railway bridges (ROB, RUB and FOB) and structural for process industries e.g. Steel,
Power plant, Chemical plants.

Feb’14 – March’17: ISGEC Hitachi Zosen Ltd., Dahej, Gujarat

General Manager
 Development of Standard Operating Procedures.
 Develops fabrication sequence diagrams and manufacturing schedules and Production planning.
 Assures compliance to the requirements including pertinent policies, procedures, work instructions, and other
related process control documents.
 Monitoring and managing manpower (Technicians and supervisors) to align the quality and delivery of products.
 Defines and communicates work assignments to shop personnel. Monitors progress of work and address issues as
needed (e.g. re-allocation of resources, alternate sequencing of jobs, resolution of operational/ technical issues).
 Assists in identifying, investigating and resolving equipment/ tooling/ process issues.
 Implementation of 5S, Kaizen
 Gives input to the development of the annual budget. Controls department expenses in order to meet approved
budget.
 Being part of team for preparation of CAPEX plan.
 Monitors and takes action to eliminate waste and drive down manufacturing costs. Assures effective and efficient
utilization of personnel and equipment (ex. Reduction of set-up and cycle times, etc.)
 Exposed to various machining activities e.g. Lathes, VTLs, HBMs, Drilling machines, CNCs etc.
 Working towards the continuous improvement, performance and output of the manufacturing unit on all shifts with
regard to Safety, Quality of processes and products, Delivery, Cost.
 Monitors key performance indicators and drives the analysis and identification of opportunities for improvement.
 Settling technical disputes/clarifications during execution of project.
 Contributes towards unit cleanliness and development of cleaning routines.
 Involved in new product development and gives input to existing product development.
 Member of few committees e.g. Root cause analysis (RCA), Canteen (CC), Lessons Learnt in previous project
(LLPP), Kaizen and 5S, Inventory Control (IC).
 Certified internal auditor.
 Drives the leadership development and leadership hiring process and works with HR.
 Delivers performance reviews, counselling / discipline, and wage increase recommendations.
 Negotiation and awarding orders to Sub- contractors, Monitoring the progress and addressing the quality issues.
 Vendor and supplier identification, audit, approval and monitoring.
 Coordination with Sales, Engineering, Purchasing and other departments.
 Provides inputs to Estimation, Proposal and Marketing departments for the enquiries, technical and commercial
point of view. Handling enquiries from Clients’ for techno- commercial aspects.
 Communicates effectively to management and other departments regarding order status and production issues.
 To conduct audits to ensure adherence to quality and safety norms, designated as trained internal auditor.
 Train and monitor the employees (Production, Welding) engaged in the production process.
 Fair knowledge of the codes e.g. ASME Sec. I, ASME Sec. IX, VIII Div.1 & 2 and Clients’ specifications.
 Handled the ASME materials like Carbon Steel, Low Alloy Steels (1.25Cr-0.5Mo, 2.25Cr-1Mo, 2.25Cr-1Mo-V, 9Cr-
1Mo-V), Stainless Steels (Austenitic, Ferritic, Duplex), Nickel Based Alloys (600, 625, 276).
 Proficient with Welding processes like GTAW, SMAW, GMAW, FCAW, SAW, Tandem SAW, ESSC, TW-SAW
 Established Automatic tube to tube sheet welding process.
 Working on SAP (ERP system) execution
 Products Handled were H-Ex, Pressure Vessels, Columns and Reactors for Fertilizers, Petrochemical Ind.

Feb’13 – Jan’14: Andritz Hydro Pvt. Ltd., Dist. Palwal, Haryana

Team Leader – Quality and Production
 Worked as Production Incharge (Fabrication shop).
 Coordinated with a team comprising of 40+ Welders, 5 Welding Engineers, 3 Numbers of Heat Treatment Staff.
 Productivity improvement and Process analysis.
 Rework analysis and planning for reductions in reworks.
 Estimation of COPQ.
 Worked as “Welding Coordinator” for ISO 3834 system.
 Worked in Quality department. Established visual inspection methodology. Internal auditing of other departments.
 As a Quality Engineer, exposed to various machines (e.g. Lathes, VTLs, HBMs) and identified the quality checks of
machined products.
 Inventory control.
 Responsible for base materials handling – Carbon Steel of thk. upto 300mm, Stainless steels (Aust. & Martensitic).
 Controlling the Inspection team at Vendor location.
 Participating in freezing the machinery requirements for the new plant and timely procurement for the same.
 Training and development of manpower.
 Managing Heat Treatment Operations.
 Controlling and managing Heat Treatment activities.
 Implementation of 5S, Kaizen
 Established Hand Held SAW machine as a replacement to GMAW process.
 Products Handled were Hydro Turbines and structures for Hydro power plants.

Jul’09 – Jan’13: Dee Development Engineers Ltd., Dist. Palwal, Haryana

Head – Welding, Manager – Production, Projects & Quality
 Establishment of non-existing Welding Department at the time of joining.
 Production of Rolled Welded pipes for various code requirements, as per client schedules.
 Handled a team of 130+ Welders, 12 Welding Engrs, 40 Technical Staff
 Improved the production from 250 meters to 600 meters of welded pipe per month, by adding few machines.
 Project management of IV & CV Casing project (P22 Material of 110mm thickness), a developmental project.
 Adeptly developed quality welding consumable suppliers at economic pricing.
 Selected, Procured, commissioned Orbital welding systems and established the process successfully.
 Established STT process for small bore sizes (upto 2”) for CS, SS, P11 grade of materials.
 Handled ISO/ASME/Client audits.
 Established methodology for visual inspections.
 Worked on establishment of ERP system.
 Developing new procedures for critical materials.
 Productivity improvement and Process analysis.
 Rework analysis and planning for reductions in reworks.
 Inventory control for welding consumables.
 Participating in freezing the CAPEX for the new plant and timely procurement for the same.
 Established two new plants and their requirements
 Training and development of manpower.
 Controlling and managing Heat Treatment operations.
 Framing policies & strategies for payment and retention of manpower.
 Reorganized Heat Treatment operations smoothly and effectively running
 Reduced the welding defects in P91 material, markedly.
 Managed the codes e.g. ASME Sec. I, B31.1, B31.3, ASME Sec VIII Div.1 and clients specifications.
 Handled the clients such as GE – Energy, GE – Oil & Gas, GE - Transportation, Alstom, ISGEC, Thermax, Adani
Power, L&T, MHI, CMIE, Doosan, GEA BTT, Man Tourbo etc.
 Worked on PED/97/23 Specs for welding qualifications.
 Responsible for base materials handling – P91, P92, WB36 (15NiCuMoNb5-6-4), P22, P11, SS and CS.

Aug’08 – Jun’09: Walchandnagar Industries Limited, Walchandnagar, Pune

Assistant General Manager (Welding Development Section)
 Implemented SAW automation of Boiler drum to Nozzle joints
 Managed preparation & qualification of Welding Procedures as per the design code & specifications like ASME
Sec VIII Div. I, NPCIL, BHAVINI, BARC, KTA, DRDE, etc.
 Handled selection, estimation and approval of welding consumables brand and manufacturers
 Established Closed arc Orbital welding machine for welding of tubes in Heat Exchangers.

Feb’07 – Aug’08: Lincoln Electric Company (Asia Pacific) Pte. Ltd., Powai, Mumbai and Chennai
Manager -Technical Support
 Performed global market survey for positioning of Lincoln Products against competition projects.
 Established STT process and pulsed SAW process (Waveform Technology) for welding of SS and Low Alloy
materials at various customers
 Handled product launch of Hardfacing materials in the market
 Planned and organized events like seminar/ service weeks to penetrate the market and position the product in it
 Identified product gaps and filled up with economically viable solutions

Oct’02 – Jan’07: Ador Welding Limited, Bhandup (W), Mumbai

Area Business Manager (Bhandup Area)
 Performed market survey for Placement of AWL Products against competition projects.
 Product costing for market penetration and stabilization.
 Added new customers into AWL clientele list by demonstrating and establishing the procedures.
 Handled Key Customers business with pre-set targets and achievements.
 Successfully established bulk-pack (MIGPAC) of MIG/MAG wire, without hampering the market of existing product
in spool form. First of its kind, indigenously developed product
 Generated technical data, against competition to help the Sales Staff

Dec’98 – Aug’02: Larsen & Toubro Ltd., Powai, Mumbai

Executive – Welding
 Instrument in Prototype Fast Breeder Reactor (PFBR) project of IGCAR (Bhavini).
 Development of GTAW and SMAW process for 9Cr-1Mo and 9Cr-1Mo(Mod.) material.
 Development of THIN WIRE SAW process for INCOLOY ALLOY 825 material.
 Handled procurement section and inventory management of welding consumables.
 Exposed to Machining processes.
 Worked on ERP (BaaN) system

Apr’97 – Dec’98: Walchandnagar Industries Limited, Walchandnagar, Pune

Deputy Chief Welding Engineer - Welding Development Section
 Development of TTS welding by GTAW with tubes PROJECTION of 30mm beyond tube sheet surface.
 Prepared a welding Sequence to control distortion within 2mm in 17 meters length for a Defence structure.
 Established Welding Procedures for welding of Penstock Material (SA 517 Gr.F)
 Had exposure to Machining processes.

Oct’95 – Mar’97: Hindalco Industries Limited, Renukoot

Mechanical Engineer - Construction Division
 Planning and execution for expansion site
 On site Inspection of Tankages erection.
 Framing Specification and Placing Orders for Pressure vessels and Heat Exchangers.
 Actively participated in feasibility and implementation of Ash Handling System of Boiler Plant.

Academic Details
 M.E. (Welding Engineering), IIT Roorkee, Roorkee (Uttaranchal), in 1996, Scored 76.6%
 B.E. (Mechanical Engineering), Aligarh Muslim University, Aligarh (U.P.), in 1994, Scored 73.3%

Certification/ Memberships
 CSWIP 3.2 (Senior Welding Inspector) certification from The Welding Institute, U.K
 CSWIP 3.1 certification from The Welding Institute, U.K
 International Welding Engineer (IWE) from International Institute of Welding
 ASNT Level – II in RT, PT and MPT

IT Skills
 Well conversant with Windows, MS Office and Primavera, and ERP System – BaaN
 Worked on SAP (ERP system) execution

Personal Details
Date of Birth: 27th May, 1974
Permanent Address: 168, Nehru Nagar, Dehradun Road, Roorkee – 247667, Uttarkhand
Current Address: H3-11, Nand Niketan, Hazira, Surat, Gujarat
Languages Known: English, Hindi, Marathi, Punjabi and Gujarati
Countries visited: USA, Latin America, several European countries.