1. CURRICULAM VITAE
Date:22-11-15
Gajanan N Sawant.
e-mail: gajsaw@yahoo.com , gajsaw@gmail.com
Cell No: +91 9591684150/ 9741979247
TECHNOLOGIST WITH 21 YEARS OF EXPERIENCE.
OBJECTIVE:
To utilize my Experience, Enthusiasm and Skills in Manufacturing Industry, that offers challenging and
supporting environment and enables me to keep update with the latest Process Deployment.
Present Company :
M/s Oriental Foundry Pvt. Ltd. Mumbai. From Aug 2014 onwards
I was promoted from Project Head to Plant Head since July 2015, after successfully completing the green field
Foundry steel casting project.
M/s Oriental Group, Mumbai, one of the biggest & well known group for supplies of various items like seat and
births, veeners, toiletries, brake blocks, Pu floorings to Indian Railways since from 35 years.
JOB PROFILE :
Successfully erected, commissioned and productionised steel foundry of M/s Oriental Foundry Pvt. Ltd, Kutch,
Gujarat, during Aug. 2014 to June 2015, a green field project for steel castings with No-bake moulding process.
The complete foundry was designed with best make equipments required to produce 1000 tons good steel castings
like Coupler body, Yoke, Knuckle, Stricker, Side bearer, Axle box housing, Side frame, Bolster which are
supplied to Indian Railways and overseas Railways.
The project includes selection of land, Foundry layout making, civil building, Substation, civil foundations for
various equipments, erection of the equipments, successful commissioning of the machines.
The Foundry equipments commissioned
1. Continuous mixer capacity 30 TPH with compaction table, roll over, motorised conveyors, fast loop
system, flooding station, mould drying oven, pouring lines, cooling lines, knockout system, sand
transporters, complete sand plant with PLC control system.
2. Electrical Arc Furnace of capacity 5 TPH with refining system with scrap yard and handling system
3. Continuous 6 TPH mixer for core making, with complete automated loop, core drying oven, core storage
system and core setting fixtures.
4. Fully computerised lab with all latest testing equipments with R&D facilities.
5. 10 ton capacity fully automatic heat treatment furnace with normalising, Water quenching and tempering
furnace
6. Foundry duty EOT cranes for material handling
7. Continuous conveyor type shot blasting machine, Room Blasting for bigger size castings
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2. 8. Fettling tools with work stations
9. Complete machine shop with all the require machines required for casting machining.
10. Auxiliaries like, 11KV substation with 5000 KVA and 2500KVA transformers, HT breakers, LT panels,
Distribution panels, Screw compressors, 500KVA DG set, Overhead and underground tank, Weigh
Bridge, Roads etc.
After completion of Project I am working as plant Head.
Previous Company
M/s Ashok Iron Works Pvt, Ltd, Belgaum, Started in 1974 is one of the biggest & well known group for
 Intricate castings in Grey Iron & S.G Iron Machined –Cylinder Blocks, Cylinder Heads, Housings –20
to 3000 Kgs/ Pc
 Farm products - Cylinder Blocks, Cylinder Heads, Transmission Cases, Clutch Housings, Hydraulic
Lift Body, from 20 kgs to 270 kgs / piece.
 Compressor Industry - Compressor Bodies, Gear Casings, Cooler Shells in S.G Iron
 Crankshafts, fuel pump Assemblies
 Integrated Setup with foundries & machine shops
 Consists of 3 foundries with Capacity 78000 Tons/Ann
 Green sand, Chemical/resin bonded moulding system
 Consists of 6 machining plants with separate set ups for different family of components to machine the
foundry produce
 Development Centre for Design & Mfg of Toolings and NPD
 Fluid Dynamics - Aluminium & Copper/Brass Cooling systems, Sheet Metal parts
 Turnover – Rs 550 Crores (2012-13)
Valued Customers :
 Cummins India
 Simpson
 Kirloskar Oil Engines
 Lister petter
 Perkins
 Tata Cummins
 MAN Trucks
 Mahindra & Mahindra
 TAFE
 Escorts
 John Deere
 Atlas Capco
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3. JOB PROFILE :
Manufacturing Head for Plant 3 Foundry from Jan 2011 to Aug 2014.
Scheduling annual, quarterly, monthly, weekly and daily production targets.
Execution and monitoring of production activities up to dispatch in terms of quality and quantity so as to
achieve the target.
Maintaining close follow up with QA, Maintenance and Process engineering to ensure smooth flow of
production.
To achieve the CLD parameters (company level data), management targets at various levels.
Experience in Grey Iron Green sand system, Alloyed Iron & S.G Iron in phenolic based 2 part system.
Promoted as Production Head for Plant 3 foundry since Jan 2011 to Aug 2014. Before taking over the
production, Plant 3 foundry was producing 1200 MT/Month of Grey Iron castings like cylinder blocks,
cylinder heads & housings with huge rejections, lowest productivity & high manufacturing cost than
budget. I was instrumental in increasing the production level to 2200 MT/Month & bringing down the
rejections & manufacturing cost to the bench mark level with the available infrastructure & resources.
Experience of working in KW High pressure moulding line, Arpa machine moulding lines, Phenolic base
two part nobake moulding system at various levels in production, maintenance & process control
department. Experience of producing quality castings like cylinder blocks, cylinder heads, compressor
housings, transmission cases, housings, differential cases etc. Core member in selection of equipments in
cylinder block & cylinder head foundry.
Responsibilities Include :
 Daily work management & manpower management.
 Customer Interaction & meeting customer satisfaction by delivering the castings with right quality.
 Conducting daily production & rejection meetings & taking necessary corrective actions based on the
feedback in the rejection meeting.
 Deep analysis by statistical process control method & conducting periodical training programs down
the line for continuous improvement to reduce the wastages & increase the efficiency of the process.
 Meeting the targets set for continuous improvement by way of Kaizens.
 As a step towards cost reduction in production we concentrated on wastages in power & fuel
consumption, Core rejections, Mould rejections, Furnace charge mix, Excess casting weight to billing
weight, 3 nos. of small Kaizens per month has to be completed by all the AM & above grade to have
continuous improvement in foundry.
 A TQM cell was formed for close monitoring of different processes in various departments. The main
motto is to bring down the rejection levels & wastages, I was identified as one of the core team
member, as a beginning step we concentrated on housekeeping activities & wastage reduction. We
were successful in doing so & have taken up projects on cost reduction parameters. As a core team
member my responsibilities include, analysing rejection level of different items along with quality
team, Identifying the corrective & preventive actions to be taken to bring down the rejection level to
meet the target specified.
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4. Equipments Handled during Production :
Moulding :
 KW make High Pressure Moulding Line with S7 400 PLC control, 90 moulds/Hr capacity with three
addition cooling lines.
 New generation shakeout of Cyrus make with electronic gearbox control system, programmable to
handle various type of thin walled & thick walled complicated castings.
 CNC controlled vent percing units for top moulds auto venting.
 Double station core setting & auto core transfer system into the moulds.
 100 TPH capacity KW make sand plant with sand handling system.
 World’s best Eirich Germany make high speed mixer, 4000 lts batch capacity with auto temp. &
moisture controller facility, with auto compactibility controller system.
 World’s best Simpson Germany make sand cooler cum premixer, 100 TPH capacity with auto temp. &
moisture controller system.
 700 mts long Vinar make overhead casting cooling conveyor with online RR breaking system.
 1,20,000 cum/hr capacity dust extraction system for sand plant & shakeout.
Melting :
 2 Nos. of 6 TPH, dual trak, 4000KW capacity each, Inductotherm Furnaces.
 7 Ton capacity fully automated Auto press pour.
 6 Ton capacity furnace scrap chargers of Electomag
 2 Ton capacity lifting magnets for scrap charging with battery backup
Core shop :
 8 Nos. of fully automatic with single minute tool change, 40 lts capacity Hottinger Germany make
cold box core shooter along with amine scrubbers & with independent luber make sand mixers.
 1 No. Fully automatic 100 lts double station Hottinger make cold box core shooter.
 12 lts, 18 lts, 25 lts & 40 lts local Span & Compax make cold box core shooters.
 13 Nos. of fully automatic Span make Horizontal & Vertical shell core shooters.
 3 Nos. of fully automatic hydraulic puller type Core drying ovens.
 Core coating & dipping stations with diaphragm pump system.
 Fully automatic 10 TPH capacity Wesman make wet fresh sand drying system with pneumatic sand
conveying system.
Fettling shop :
 2 Nos. of BMD make decoring machines for removal of core sand from the casting.
 Fully PLC controlled, 25 Tons & 12 Tons capacity Stress Relieving Furnaces for blocks & heads.
 3 Nos. of Disa make Hanger type shot blasting machines with dust extraction system.
 Patel Furnaces make Nozzle blasting machine for cylinder heads & cylinder blocks.
 4 Nos. of Tocol make Snag Grinding machines for cylinder blocks & for cylinder heads.
 Local make casting painting booths.
 Boroscope facility for checking water jacket of cylinder block & cylinder heads.
 Hydroblasting facility for cylinder head cleaning.
Utilities :
 110 KV/11KV, 10 MVA capacity outdoor substation
 2000 KVA, 1500 KVA distribution transformers
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5.  2 Nos. of 11KV alternator D.G sets
 Reciprocating & screw compressors
 Under slung hoists & EOT cranes from 500kgs to 10 tons capacity
Special techniques:
 Conversant with quality systems and relevant techniques like TPM, SPC, Kaizen , Poka Yoke, Six
Sigma.
 A competent professional with ample experience in Green field projects, successful erection &
commissioning, Plant Maintenance, Plant operations, Process improvement & Man management.
Team Management:
 Training, monitoring, resolving interpersonal issues & leading to achieve individual & group targets.
 Development of a strong second level team to take up higher responsibilities across the organizations.
Maintenance cum Projects Head from May 2010 – Dec 2012
 During these experience, I was exposed to all types of equipments like latest S7 400 PLC, SCADA,
servo drives, hydraulic proportional valves, CNC programming of snag grinding machines, 5TPH
thermal reclaimation plant for 2 part no-bake moulding, Press pour programming, Latest PLC
controlled heat treatment furnaces, 110KV substation with 10MVA power transformer.
 Exposed to all energy efficient, cost saving equipments & techniques & methods.
 Heading Maintenance & Production department & taking care of preventive, predictive & breakdown
maintenance activities in foundry along with production targets.
 Operation & maintenance activities of all the utilities like 110KV electrical substation, screw
compressors, LOT LPG system, DG sets, cooling tower systems.
 Operation & maintenance activities of all material handling systems & safety related equipments.
 Spares part planning, inventory control as per budget, long & short shutdown planning.
 5 s, Lean management concept, TPM concept implemented & sustain zero accidents in foundry for
continuous 1 year.
 Conducted an experiment & redesigned the work space layout for lean work flow at core shop &
fettling shop.
 Reduced maintenance inventory cost from 75 lacs to 25 lacs.
 Trained the operators & staff for concepts like Kaizens, kanban, lean & work standardization.
 Redesigned hyd & pneumatic circuits to reduce breakdowns of HPML.
 Setup time reduction from 120mins to 5mins for all the hottinger core shooters by SMED
implementation.
 Designed & developed indigenous spares of imported machines resulting in huge cost savings.
 Developed & implemented maintenance management system.
Responsibilities Include :
 Providing leadership to the Maintenance teams for upkeep of machineries and Utilities for smooth
manufacturing operations.
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6.  Implementation of technological changes in executing automation, indigenization ,cost & energy
saving techniques & modifications to achieve substantial reduction in expenditures and enhance
uptime.
 Monitoring maintenance expenses with optimum utilization of resources, budget Planning & Cost
Management and Controlling of spares inventory and their management with ERP.
 Tracking and analyzing daily Breakdowns, scheduling & Implementing Preventative, Predictive &
Time Based Maintenance programmes to improve the efficiency of the system or the equipment
undergoing maintenance.
 Preparing reports on Maintenance performance & technical data of various equipments, spare parts,
labour and machines.
 Periodical safety tests and Inspection by competent agencies on material handling equipments,
cranes, pressure vessels, electrical equipments.
 Planning, Implementation of TPM.
 Carryout instruments calibration & Equipment validations.
 Co-ordinating with outside agencies like vendors, third part maintenance service providers for AMCs.
 Liasoning activities with govt authorities Like Electricity board, Pollution control board.
 Training of employees on TPM, Safety issues, fire fighting, Environment issues, maintenance
techniques and Improving maintenance activities to minimize the downtime.
 People management, identify, evaluating and rewarding of executive /supervisory staff.
Projects Head for all the three Foundries from April 2000- April 2010
 As a project incharge I was fully responsible for designing & layout preparation as per the process &
material flow needs, foreseeing performance bottlenecks, layout finalisation, equipment selections,
follow-ups, erection & successfully commissioning, plant trials & handing over to production.
Ensuring effective site management & discipline to ensure safe execution of the projects.
Plant 3 Foundry Project
 This project was a green field project in 34 acres of land fully automated green sand moulding of
48000 TPA capacity with KW Germany make High pressure moulding line of 90 moulds/hr capacity,
100 TPH KW India make fully automated sand plant, 4000lts batch size Eirich Germany make mixer,
100 TPH Simpson sand cooler, 2 nos. 6 TPH 4000 KW capacity Inductotherm Medium Frequency
Furnaces, Vibratory scrap charger, 7 Ton capacity Fomet make Auto press pour, Pump house, Material
& sand testing lab with spectrometer, Hottinger make cold box core shooters, Span make shell core
shooters, Core drying ovens, Core storage & handling trolleys, Decoring units with waste sand
disposal system, Disa make Hanger type shot blasting machines with dust extraction system, Nozzle
blast machine, Snag grinders for blocks & heads parting line grinding, Overhead casting cooling
conveyor, Pulsejet dust extraction system, Fume extraction system for furnaces, Stress relieving
furnaces, Utilities like 110KV/11KV 10MVA electrical substation, DG sets, Reciprocating & Screw
compressors, Cooling towers, Wesman make fully automated 10TPH capacity fresh sand drying &
pneumatic sand conveying system. Various underslung hoist from 500 kgs to 10 Ton EOT cranes for
material handling.
I have successfully erected & commissioned the foundry plant no. 3 within target time, taken trials &
handed over to production.
Plant 2 Foundry Project
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7.  This project of Plant 2 was for two part no-bake moulding foundry expansion to increase the plant
capacity from 1250 MT/month to 2500 MT/month.
 This projects includes layout finalisation, equipment selection, follow-up, erection & commissioning
by building expansion, installing additional equipments like 5 ton capacity Disa make fully automated
shot blasting machine with dust extraction system, New generation Omega UK make completely PLC
controlled stationary knockout size of 4m x 5m & 4m x 4m with mechanical iteration system along
with dust extraction system, 25 Tons batch size dual trolley stress relieving furnace with PID
controller, Kaiser make screw compressors, New core drying oven with slat conveyor system, Mould
drying oven with slat conveyor, High rise core storage system, rearrangement of cold box core
shooters, shell core shooters, 60 TPH capacity Omega make continuous mixer, 20 Ton capacity
compaction table, Relocation of 33KV/11KV complete electrical substation.
The above project was completed within target time & without affecting the day to day production.
 State of art 5 TPH capacity Richards UK make Thermal Reclaimation Plant for phenolic base two part
nobake moulding whose project cost was 450 lacs was successfully productionised in three months
time along with LOT LPG system in which waste out going moulding sand is been thermally
reclaimed to get fresh sand which is used for cold box core making. Net saving of Rs. 1000/- per ton
w.r.t fresh sand buying i.e sand required per annum is 12000 tons hence saving of 120 lacs per annum.
Senior Engineer Foundry tooling design, manufacture & prove out from Oct 98 to Mar. 2000.
Joined Ashok Iron Works Pvt. Ltd, Plant -1 on Oct 98 as a foundry tooling Sr. Design Engineer having
following significant contributions.
 First person to introduce AutoCad system in AIW group for generating casting drawings, machining
drawings, tooling drawings, Jig & Fixtures eliminating drawing boards.
 Maintaining & looking after complete Designing of casting gating system, casting methoding
drawings, Pattern equipment drawings, core box design to suit core shooters.
 Introduce foundry toolings manufacturing in AIW by 3D Modelling using CAD/CAM CNC route &
stopping manual manufacturing of foundry toolings. First tooling developed through CAD/CAM was
3 & 4 cylinder block for M/s Lister Pitter, UK from M/s Tool Room Pune.
 Developed foundry toolings manufacturing vendors in Kolhapur & Pune.
 Taking follow-up & getting the foundry toolings manufactured from outside vendors, core making,
mould making, pouring the sample casting, proveout the casting as per specifications of the customer
& handing over to production.
 Cost estimation for new enquires of casting development.
PREVIOUS COMPANY
1. 10th
Aug 1995 to 05th
Oct 98 with M/s Bemco Hydraulics Ltd, Belgaum, as Sr. Design Engineer
Significant contribution
 Here I was working in design department as a Sr.Design Engineer.
 C type std Hydraulic presses designed & manufactured from 2 ton capacity to 100 tons capacity.
 H type non std hydraulic presses designed & manufactured from 5 ton capacity to 500 tons capacity
for deep drawing presses, power compacting, special purpose presses as per customer requirement.
 Total design of machine fabrication structure, designing of complete hydraulic circuit & power pack,
selection of materials.
 Developed software to calculate the stresses developed in machine fabrication structure before actual
fabrication of the structure.
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8.  Developed standardisation in C type & H type presses resulting in huge savings in terms of manpower
& cost.
COMPANY PROFILE: M/s Bemco Hydraulic Ltd, originally an Engineering Craftsman's shop
in the late thirties has risen to be a premier producer of HYDRAULIC Presses equipments. It is located in
Belgaum, Karnataka, a southwestern state in India.
BEMCO has a well planned and adequately equipped manufacturing set up where every infrastructure is
available to design, develop and produce a mega range of HYDRAULIC presses & equipments.
BEMCO is one of the oldest, biggest reputed leading Manufacturer & Supplier of the latest technology in
all types of standard & non standard hydraulic presses, hydraulic power packs & hydraulic cylinders,
hydraulic SPMs, Extrusion presses, Hydraulic high pressure pumps, hydraulic steering systems for defence
which is used in tanks, powder compacting for ordinance factory.
BEMCO, has widely spread clientele round the world, major clients are :
Indian Railways Maruti Udyog Ltd., TVS Motors Ltd., Bajaj Auto Ltd., Hyundai Motors Ltd., Tata
Motors Ltd., Hindustan Aeronautics Ltd., Honda Motors Pvt. Ltd., Defence Industry
ACHIEVEMENTS
 Rewarded as Best Performer of the year during 2007 – 2008
 Improvements, modifications and Indigenisation of spares for various imported equipments through
modification and re-designing, achieved cost saving of Rs.80 lakhs.
 Erected, successfully commissioned & Productionised 5 ton per hour capacity Thermal Reclaimation
Plant of M/s Richards, UK at plant 2 for two part phenolic mould making system, achieved cost saving
of Rs. 120 lacs/annum.
 Conversion of all the SRF, core drying oven, mould drying oven burners from single fuel to dual fuel
(HSD/LPG) operating system, in which net saving of 48 lacs per annum.
 Energy Conservation projects & power factor brought near to unity.
 Automation of machinery for manpower saving and productivity improvement through industrial
engineering method.
 Maintaining uptime of machineries more than 93%.
 Worked & got trained under German consultants for 4 years for foundry projects, analysing & solving
quality related casting defects.
Key Skills and Strengths.
 Good communication and interpersonal and Strong leadership skills .
 Strong technical, Creative and administrative and abilities.
 Ability to guide subordinates, to complete targets by suggesting easiest, simplest and effective
methodologies to achieve quality production excellence.
 Imparting on-job practical and theoretical trainings periodically.
 Motivating people to adopt poka yoke concepts where ever possible.
Technical Qualifications.
BE (Mechanical Engineering), from Gogte Institute of Technology, Belgaum, (1995)
On job Industrial Engineering Training through PSG institute of management Coimbatore.
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9. IT Skills :
 M S Office, M S Projects, Auto Cad, 3 D Modelling, ERP package, CNC programming, PID
programming, Scada
 Knowledge of PLC software like Siemens S7, Allen Bradley
PERSONAL INFORMATION
Name Gajanan N Sawant
Sex Male
Date Of Birth 29-09-1971
Nationality: Indian
Marital Status Married, one Daughter & one Son
Passport No J4651226
Hobbies Reading, Listening to old music, Photography, Travelling
Languages Known English, Hindi, Marathi, Gujarati and Kannada
Education B.E Mechanical
Email ID: gajsaw@yahoo.com, gajsaw@gmail.com
Permanent Address: Gajanan N Sawant
Ganesh Vihar Appartment, Flat No.405,
Forth cross, Bhagynagar, Belgaum - 590006
. Cell No: : +91 9591684150/ 9741979247
I Sawant. G. N, do hereby confirm that the information given above is true to the best of
my knowledge.
GAJANAN N SAWANT
BELGAUM.
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