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DINESH MANGAL B.E.Mechanical, DIM
Mobile: +91 7774073601 Current Location: Solapur dineshmangal@rediffmail.com
P&L MANAGEMENT ~ SAFETY MANAGEMENT ~ PROJECT OPERATIONS~PLA NNED MAINTENA INCE
TOP MANAGEMENT RESUME- CEMENT INDUSTRY
A leader with 27 years of impactful experience in Cement Industry that includes more
than 9 years of Leading and Project Managing multiple plant operations, maintenance &
safety standards of reputed industrial manufacturing plants
Value
Proposition
Delivering organizational productivity & profitability by consistently
achieving 100% safety environments & quality benchmarks through
operational & Leadership excellence
Specialization
 BUDGET & COST CONTROL, PROCESS ENGINEERING & IMPROVEMENT
 PLANT MAINTENANCE & OPERATIONS, PROJECT MANAGEMENT
 RESOURCE PLANNING & OPTIMIZATION, PROCESS IMPROVEMENT
 QUALITY ASSURANCE & CONTROL, INSTALLATION & COMMISSIONING
 MAN MANAGEMENT, HANDLING CRITICAL IR ISSUES, INTERVIEWER SKILL
Quality
Concepts
 WCM, TPM, KAIZEN, JIT, Six Sigma, RBM,
 World’s Best Safety Standards, ISO 9001 & 14001,
 OHSAS 18001, SA 8000 STANDARDS
 10000 TPD Brownfield Integrated Plant Erection & Commissioning
 0.95 MMTPA Greenfield Grinding Unit Erection & Commissioning
 VSK Separator Installation in Cement Mill Circuit with Polycom
 Up-gradation of Plant capacities from 2300 TPD to 3000 TPD in Line I & II
 Inter-transfer Project of Cement through Pipe Conveyor
 Commissioning & Installation of Water Spray System in PH Down Comer Duct
and Cyclone & Cooler
 Commissioning & Installation of Modified Classifier of VRM
 Commissioning & Installation of Boltless Liners in Cement Mill
Top Projects
Managed
Key Roles
Head
 Last Role : Plant Head – ZUARI CEMENTS –www.zuaricements.com
with responsibility for managing Greenfield Grinding Unit Project of
0.95 MMTPA Capacity
 Previously at ULTRATECH CEMENT LTD – www.ultratechcement.com
 Departmental Head – Mechanical – Pre Clinkrizarion and post
clinkerization both for three units
 Departmental Head- Projects Co-ordinator – For 10000 TPD
Brownfield Project
 PROJECT MANAGEMENT– Leading and overseeing multiple Project planning
& implementations, formulating budgets to ensure projects are executed
within prescribed cost, timeframe &quality standards
 PLANT MAINTAINENCE & OPERATIONS– Deploy and lead continuous
preventive maintenance initiatives of various plants & units to ensure safety,
equipment & machinery efficiency & Project continuity
 SAFETY MANAGEMENT– Consistently align and conform to the highest safety
standards of the industry ensuring zero percentage injury or loss across
locations
 QUALITY MANAGEMENT - Implementing quality tools to ensure process
Solutions
offered

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capability as per specification requirements, monitoring by control plan
preparing and implementing improvement & corrective action plan
As Project Lead / Plant Head well Evolved and positioned to :
 Manage, develop & lead people and projects in Cement Industry by providing
organizational leadership, resource management & crisis management
 Handle multiple projects across locations that involves supervising all functions
(safety, finance, plant operations, quality management, suppliers, inventory
management, labor problem, coordinating with sales team)
 Resourceful in executing & completing various projects with a flair for adopting
the modern methodologies; complying with quality standards
Role
Scalability
 2011 – Received “Best safety train the trainer” Award.
 2010– Recognized as “Best Consistent Employee” of the Group by
management on completion of 20 years association with the group
 Awarded for “Best suggestion in inventory management and power
reduction” in coal mill
 Bagged “group best results in alternate fuel consumption and TSR %”
as Mechanical Head in Vikram cement.
 Bagged Group Best Results in Clinker Grinding and Mill
Availability(22.5Hrs) for all three Mills in year 2007-08
Awards &
Recognition
 Acted as WCM Sub-Committee Supply Chain Management and managed
JIT implementation
 Functioned as member of Organizational Health Improvement
Committee, 2009
 Chairman of Planned maintenance and machine guarding safety
standard implementation team at Ultra Tech
Memberships
& Affiliations
 TPM Internal Auditor for improving productivity and overall equipment
efficiency (OEE)
 ISO Systems Auditor & Department Representative for ISO 9001, 14001,
OSHAS 18001, SA 8000 Systems
 TPM Circle Leader for continuous Kaizen to reduce power & improve OEE,
 Effective Jishu-Hozen (Self Maintenance) & 5S Implementation in the circle
Quality
Audits
 Ensured project completion on time with 100% safety at sites during Erection &
Commissioning activities across all sites
 Resolved various bottlenecks across maintenance operational activities like Long
Pending Problem in Coal Mill frequent tripping through high DP in Main Bag
Filter after Petcoke Grinding, Kiln tripping with High support roller bearing
temperature
 Managed the maintenance of Clinker Transport, Gypsum Transport,
Deep Bucket Conveyor, BHP &Aumund Bucket Elevators, Belt Conveyors, Apron
Conveyors, Screw Conveyors & Pneumatic Conveying Systems
 Significantly involved in “Inventory Reduction” project based on Six Sigma
Select
Successes

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methodology
 Efficiently achieved zero fatality target and completed the project earlier then
the similar group projects at different locations
LEADERSHIP EXPERIENCE OVERVIEW
ROLE - PLANT HEAD – PROJECTS – FEB 2014 TILL DATE , Team Size -
25 members and directly reporting to Central Project – Head
 Currently managing a Green Field Project of 0.95 Million Turnover
per annum
 Successfully achieved a 100% safe working environment across the plants
 Consistently achieved Zero Injury till date
 Successfully brought the project to the commissioning stage in less than a
year time despite highly volatile surroundings at project location
Zuari Cements
Achievements
ROLE- DEPARTMENTAL HEAD – MECHANICAL – JUL 2011 TO FEB
2014
 Team Size - 35
 Headed all three units Mechanical maintenance and packing plant, LS
crushing and transport and raw material including coal, Gypsum, Flyash
and plant utility operation team
 Headed WCM KFA planned Maintenance team & safety standards Audit and
Protocol implementation team
 Headed machine guarding safety standard implementation team
 Achieved Highest Cement dispatch per month, per packer per shift and
through rail with minimum demurrage
 Achieved Lowest power consumption i.e. 19 units per ton PPC of cement
mill in group
 Acknowledged for Best Safety Performance for completion of major kiln
shutdowns with zero unsafe acts observation
Vikram Cement
(ULTRATECH)
Achievements
ROLE - DEPARTMENT HEAD – PROJECTS – APR 2008 TO JUN 2011
 Headed complete project department with maintenance & operations of
very unique site (Uphill & Downhill) of post clinkerization area including
additives & coal handlings & storage
 Managed WCM Plant maintenance Sub-committee for unit & headed two
nos. Dupont’s safety standards implementation committee of unit
 Successfully completed project activities of New Line of 10000 TPD
APCW II
 Efficiently achieved zero fatality target and completed the project earlier
then the similar group projects at different locations
 Significantly commissioned world first commissioning of Loesche Mill LM
69.6
ANDHRAPRADESH
CEMENT WORKS
(ULTRATECH)
Achievements

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Section Head –
Vikram Cement
ROLE - SECTION HEAD – CEMENT MILLS & CLINKER TRANSPORT
 Handled maintenance operations of all 3 Cement Mills, Roller Press, VSK
Seperator , Gypsum, Flyash& Clinker Transport (1 Ball Mill of KP with Roller
Press & VSK Seperator& 2 Ball Mills of M/S KHD Close Loop)
 Served as WCM Team Leader and spearheaded performance improvement
initiatives in the Cement Mill & related area with respect to enhancing
productivity and reducing machinery downtime & power consumption
 Efficiently commissioned Pipe Conveyor; successfully conducted the
installation & commissioning of VSK Seperator
ROLE - SECTION HEAD - COAL MILLS & FIRING SECTION
 Managed complete maintenance operations of all 3 Coal Mills and Coal Firing
Section (1 Mill of KP RMK 27/13 Cap. 35 T Max; 2 Mills of M/S Loesche LM
19.20 Cap. 21 T)
 Efficiently resolved the long pending dust emission problem in Coal Mill
through Main Bag Filter after petcoke grinding
 Instrumental role in the successful installation of Inert Gas System
 Significantly ensured lowest ever consumption of power with “Pet Coke
Grinding”
 Deftly minimized coal fluctuation (up to range of 0.2MT) in coal firing area,
helped in avoiding poor quality of clinkerisation& rate loss
Section Head –
Vikram Cement
Achievements
ROLE - SECTION HEAD - KILN SECTION
 Managed complete maintenance operations of all 3 Kilns ( 2 nos of KHD
with capacity of 2800 MT and 1 no of Krupp Polysious with capacity of
4400 MT)
 Responsible for 3 Six-Stage Pre-Heater & Grate Coolers with Clinker
Transport and Kiln Feed System of all three lines
 Achieved non-stop running of Kiln for 138 days with lowest ever
breakdown in the history of the company.
 Successfully achieved highest production of Clinker in all three lines
 Significantly ensured lowest ever power consumption in two of the three
units and lowest ever heat consumption in all three units
Section Head –
Vikram Cement
Achievements
Section Head –
Vikram Cement
Achievements
ROLE - SECTION HEAD –SHIFTS OPERATION, INVENTORY CONTROL
& BUDGETING PLANNING
 Served as In-charge of mechanical shift operations of all three units
&Budgeting and Planning alongwithinventory control of all technical
departments
 Significantly reduced inventory level by Rs. 90 Lacs by identifying
common inventory between other sister units
 Deftly developed import substitutes of critical and costly spare items
which led to 30-40% cost savings

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Section Engineer–
Vikram Cement
Achievements
ROLE - SECTION ENGINEER–LINE 1&2CEMENT MILLS, RAW MILLS
AND COAL MILLS AND PACKING PLANT
 Responsible for the maintenance of Close Circuit Mill and Open Circuit Mill
with the capacity of 150 TPH & 130TPH respectively
 Responsible for the maintenance of two Loesche Mill LM 32.40 for Lime
Stone Grinding and two Loesche Mill LM 19.20 for Coal Grinding
 Deftly handled the operation and maintenance of Haver&Boecker AFE &
ME type Roto Packers and Bag Conveying System for Truck / Wagon
Loading & Cement Silo Cleaning, Cement Extraction System, etc.
 Successfully achieved lowest breakdowns of Cement Mills with ever
lowest maintenance cost.
 Significantly conducted installation of Inter-Transfer Cement Conveying
System between two mills to cement silos
 Successfully handled the maintenance of Raw Coal Crusher, Coal
Transport System & Lime Stone Re-claimer & Transport System
 Significantly achieved maximum average output of Raw Mills by way of
modification in Classifiers
 Skillfully increased life cycle of costly spares by 3 times by way of
improvement in metallurgy
 Successfully handled the installation of new ME type Roto Packer
Machine
 Skillfully reduced bag burstage problem by streamlining the Conveying
System
CAREER SNAPSHOT
ORGANIZATION ROLE TENURE
Zuari Cement Ltd. Plant Head – Projects Feb 2014 Feb 2015
Vikram Cement
(Ultra Tech)
Department Head – Mechanical Jul 2011 to Feb 2014
Department Head - Project Apr 2008 to Jun 2011
Section Head - Cement Mills & Clinker
Transport Section
Nov 2006 to Mar 2008
Section Head - Coal Mills & Firing Section Dec 2005 to Oct 2006
Section In-charge – Kiln Apr 2002 to Mar 2005
Section In-Charge - Shift Administration
& Inventory Control
Oct 2000 to Mar 2002
Section In-Charge - KHD Cement Mill -
Tube Mill
Aug 1998 to Sept 2000
Section In-Charge - Raw Mill & Coal Mill
Vertical Roller Mill
Jun 1994 to July 1998
Section Engineer - Packing Plant July 1990 to May 1994
Graduate Engineer – Trainee Jul 1989 to Jun 1990
Saurashtra
Chemicals
Management Trainee Jan 1989 to Jun 1989
Academics
1988 – B.E. (Mechanical)Shri GS Institute of Technology & Science, Indore
1996 – Diploma (Business Management) from IGNOU, New Delhi
Pursuing – MBA (Strategic Management/Finance) - Global Next University
of Manipal Group – Completion – Mar 2016

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Certification
Persuing – PMP from Global Next University of Manipal Group
1987 - Industrial & Business Management from DAVV, Indore
2001 - Systems Management (CPISM) from APTECH
PERSONAL DETAILS
Date of Birth 21st June 1965
Address 70, Veershaiv Nagar, Bijapur Road, Solapur (Maharashtra) 413004