Ram - Operations Manager - Athlone Park, Amanzimtoti, South Africa

Manoj Ram

Athlone Park, Amanzimtoti, South Africa

Services

Operations Manager

Summary:

Operations Management

Work History

Operations Manager (OPCO Member)

Management of the Production

From June 2010

Training and SHEQ departments.
Management of the maintenance team including Maintenance Supervisor, fitters, boilermakers, electrician and instrument technician.
Management of projects and modifications with the Project Manager reporting directly to me.
Preparation and managing of budgets for capital expenditure, production and maintenance
Plant process optimisation with regard to throughput and quality
Responsible for the plant SCADA system and plant manufacturing execution system (MES)
Plant administration, including writing of operating instructions, reports and performing investigations.
Process engineering including designs reviews, drawings and Hazops, etc

Completed AECI Management Development Program. Graduated in 2012

Special Job Functions:: Chairperson of the SHE committee
: Action Group Leader for emergency situations
: Technical liaison between Resinkem and Georgia-Pacific Chemicals LLC) Dangerous Goods Legislation Co-ordinator
: Process Safety Management Co-ordinator
: Willis Insurance risk management Co-ordinator
: ERM energy optimisation Co-ordinator
: Authorised signatory for payments
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Appointed as responsible person for buildings, machinery and pressure vessels.
Attend the Board of Directors meeting biannually

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Previous Post: Plant Engineer (OPCO member)

Operations Manager

November 2006 - June 2010

Main Job Functions:
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Responsible for the proper mechanical and process operation of the plant while optimising its performance. Responsible for conducting Design Reviews and HAZOPs
Managing plant modifications Handling plant and incident investigations
Maintenance and updating of plant operating instructions

: Preparation and managing of budgets for the plant production, safety, training and maintenance departments Initiate, monitor and control capital expenditure proposals
: Responsible for managing the maintenance team
: Conducting audits on the various plants, laboratory and workshop
: Managing schedules for maintenance of plant equipment Responsible for managing the Training department Responsible for managing the SHEQ department Counselling of personnel
: Managing projects from design to commissioning Approval Manager for plant modifications Responsible for overseeing the plant network computer systems Performing safety and housekeeping audits on the plant
: Interviewing and selection of plant personnel Conducting of process and incident investigations
: Performance appraisal of employees
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Special Job Functions:: Chairperson of the SHE committee
: Action Group Leader for emergency situations
: Technical liaison between Resinkem and Georgia-Pacific (Visited Georgia Pacific's plants in 2007 and participated in Process Hazard Analysis) Dangerous Goods Legislation implementation Representative
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PREVIOUS EXPERIENCE (Continued)
Name of Company: SA Bioproducts (Pty) Ltd (Previously AECI Bioproducts)

Address of Company: Private Bag X510, Umbogintwini, 4120.

Type of Company: Highly automated Fermentation / Chemical Plant, involved in the manufacture of Lysine and Threonine. (Amino acids used for animal feed supplement).

Process Manager

Management of the Production

October 2005 - October 2006

Main Job Functions:: Management of the Production team
: Responsible for the management of the entire plant, namely the fermentation plant, the downstream processing plant and the plant laboratory Planning and co-ordinating the fermentation plant's production Monitoring of the plant's performance Attending daily production management meetings
: Managing the budget for the plant laboratory and the fermentation plant Planning and scheduling of maintenance work Conducting audits on the plant and the laboratory
: Managing schedules in the plant Laboratory and the plant
: Counselling of personnel
: Writing monthly production reports Approval Manager for plant modifications
: Authoriser for plant operating instructions
: Training of plant personnel on fermentation
: Approval Manager for deeming trainees competent Performing safety and housekeeping audits on the plant
: Interviewing of new plant personnel
: Accident investigations
: Process investigations
: Plant optimisation
: Performance appraisal for plant personnel
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Special Job Functions:: Member of manpower selection committee Action Group Leader for emergency situations
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PREVIOUS EXPERIENCE (continued)

Process Engineer - New Business Development

S.A Bioproducts (Pty) Ltd

October 2001 - October 2005

Period Worked: October 2001 - October 2005 (48 months)

Reason for Leaving: Promoted to Process Manager
Main Job Functions: Design and process implementation of small projects
: Plant optimisation studies
: Energy conservation investigations
: Administrator for the modification proposal system
: Administrator for the process drawing system Budgeting and forecasting of capital costs
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Work Assignment - Denmark
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Involved in the commissioning of the Agroferm Lysine plant in Denmark (Esbjerg), involving;
Quality control supervision of sterile vessels and sterile piping

: Validation of fermenter batch sequences Commissioning of fermenters, sterilisers and associated equipment Operation of the plant to evaluate design capabilities
: Recording of process data and reporting to Agroferm management
: Optimisation of fermenter performance Fermenter contamination case studies
: Training of personnel
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Threonine Plant Project: Involved with the design, construction and commissioning of the new Threonine Plant involving; - Conceptual design - Design Reviews - Hazops - Involved in compiling the basic engineering package - Control and Operability studies - Conducting of Safety Assessments - Drafting Operating instructions - Internal Environmental Impact Assessment - Quality control supervision during plant fabrication - Commissioning Leader for Cold and Hot plant commissioning - Performance evaluation of the plant - Plant Optimisation - Training of personnel


PREVIOUS EXPERIENCE (continued )

Process Engineer - Production

S.A Bioproducts (Pty) Ltd

May 1998 - September 2001

Period Worked: May 1998 - September 2001 (41 months)

Reason for Leaving: Promoted to the Process Engineering Department

Main Job Functions
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Monitoring and optimisation of the Plant Fermenters for maximum Lysine production
Fermenter run-analysis to determine yield, productivity, production and other fermenter parameters

: Weekly technical presentation of fermenter performance to Operations Management Contamination case studies on contaminated fermentations Process Investigations
: Techno-economic studies Plant Trouble shooting
: Plant modifications (requiring Design Review, design calculations, Hazops, isometric drawings, implementation, commissioning and handover to Operations) Writing of Technical notes Writing of Operating Instructions for revised operating procedures and for new modifications to the plant Writing of fermentation monthly reports Evaluating variable cost of production Conducting feasibility trials on new raw materials Provision of technical support for African Products Corn Steep liquor Plant (in Germiston) Monitoring of plant raw material consumption and costs.
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Special Job Functions: Stand-by for Process Manager
: Planning and co-ordinating Plant shutdowns
: Training of Plant personnel
: Safety/STEP audits and investigations
: SHE Committee Chairperson


PREVIOUS EXPERIENCE (continued.)

Shift Team Leader

S.A Bioproducts (Pty) Ltd

September 1994 - April 1998

Period worked: September 1994 - April 1998 (44 months)

Reason for leaving: Promoted to Process Engineer position

Main Job Functions: Commissioning of the Lysine Plant which involved; - Writing of commissioning and start-up plans. - Writing of operating instructions. - Liaising with construction to ensure that the plant is built according to design. - Starting up of various sections of the plant and optimising its performance
: Normal duties included; - Operation of the plant to achieve desired performance and yields - Planning of product throughput and fermentation runs - Maintaining required inventory of raw materials - Identification and scheduling of maintenance - Plant trouble shooting - Maintaining and promoting a safety and environmental ethic in accordance with legislative requirements.
: Special duties entailed; - Conducting process investigations, contamination case studies and optimisation studies - Chairperson of the SHE Committee - Conducting accident / near miss investigations, STEP audits - Assisting with training of personnel
: Unit Operations; - Gained intimate knowledge of fermentation, fermentation design principles, sterilisation and sterile techniques. - In depth operational experience gained in Granulation and solids material handling. - Accumulated extensive knowledge on Ultra- filtration and Evaporators


PREVIOUS EXPERIENCE (continued.)
Name of Company: Sasol Fibres

Type of Company: Acrylic Fibre Manufacturing (wet process)

Shift Team Leader

March 1993 - August 1994

Main Job Functions
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Supervision of Chemical Plant personnel during period of shift while ensuring the safe and efficient plant operation
Allocation of jobs and directives to personnel, as per shift instructions.
Co-ordinating of maintenance jobs.

: Monitoring of all plant parameters and Laboratory results to ensure desired quality and production. Process optimisation to ensure improved plant performance
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Special duties performed:: Training of personnel.
: Plant personnel performance appraisals and hearings Shift Safety Representative.
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Unit Operations:: Gained in depth knowledge of multiple effect Evaporators.
Experience gained in solvent purification
: Experience gained on Acrylic fibre Spinning Line
: Knowledge of Ion Exchange derived.

PREVIOUS EXPERIENCE (continued)
Name of Company: Illovo Sugar (Previously called Smithchem - A Division of C.G.Smith Sugar Ltd)

Address of Company: P.O. Box Sezela, 4215.

Type of Company: Chemical Processing of Furfural, Fufural Alcohol and Dicetyl

Post Held: Draughtsman (contractor)

Period Worked: August 1992 to March 1993 (8 months)

Reason for Leaving: Secured permanent position with Sasol Fibres.

Main Job Functions
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Updating of existing Piping & Instrument Drawings to correspond to "As Built" status Tracing of plant pipework and initiating new drawings for areas without P & ID's.
Drawing of Isometrics, P&ID's, sketches and GA's.

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PREVIOUS EXPERIENCE (continued)
Name of Company: Engen Refinery (formerly known as Genref ltd)

Address of Company: 465 Tara Road, Wentworth, 4052.

Technical Assistant

Petrochemical Refining

May 1990 - July 1992

(Assistant to the Chemical Engineer)

Period Worked: May 1990 to July 1992 (26 months)

Reason for Leaving: Termination of contract after achieving Higher National Diploma, due to policy of company, i.e. allowing only training for diplomates, with no opportunity for permanent positions

Main Job Functions
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Monitoring of the Plant's performance and subsequently optimizing of its performance.
Plant trouble shooting.

: Implementing modifications for better / safer / more economical operation of the unit.
: Drawing of piping and instrumentation drawings for modifications. Liaising with Operations on the most productive and economical way to run the unit.
: Overseeing chemical additive injection facilities in conjunction with product specification. Inventory control of all catalysts and supervision of loading during shutdowns.
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PREVIOUS EXPERIENCE (continued)

Special Laboratory Technician

Engen Refinery

August 1989 - May 1990

Period Worked: August 1989 to May 1990 (10 Months)

Reason for Leaving: Completion of required Laboratory In-Service Training for the Chemical Engineering Diploma.
Main Job Functions: Calibration of analytical measuring instruments
: Determining the precision and accuracy of analytical measuring instruments. Writing/revising test methods.
: Laboratory analysis of refinery intermediate and final products
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Projects

Commissioning

Commissioned Lysine production plant in Esbjerg, Denmark

Qualifications & Certifications

Business Management

Durban University of Technology

Chemical Engineering

Durban University of Technology

Chemical Engineering

M.L. Sultan Technikon, (now Durban University of Technology)

English

Reservoir Hills High Secondary

Finance

University of Kwa-Zulu Natal - Graduate School of Business

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