Madhav Bapat

Targeting senior level assignments in Manufacturing, Project Management

& Project Execution with a leading organization

Career Summary Contact

A competent professional with over 26 yearsof rich experience in directing Project [email protected]
Management, Shop floor execution & Manufacturing of Heavy Engineering Equipment for
+91-9909035683
Fertilizer & Petrochemical Plants, Refineries, Power Plants, Nuclear Equipment’s &Defense
Sectors, Techno-commercial Operations, and Reporting & Documentation
Proven capabilities in enhancing the operations, optimizing resources & capacity and Core Competencies
escalating productivity & operational efficiencies
Excels in leveraging analytical skills (Internal & External Root Cause Analysis) and lean Manufacturing Planning & Control
mechanism for new product development
Headed manufacturing planning for Fabrication of Waste Heat Boilers, Steam Drums, CG Process Improvements
Boilers, RG Boilers, Carbamate condensers, Urea Strippers, Methanol convers & Various
Heat Exchangers and so on
Operation & Execution
Excels in the latest fabrication techniques and international standards & codes like ASME,
IBR, TEMA and so on
Rejection Analysis
Successful in identifying strategies to reduce operation cost and cycle time
Knowledge of prime welding processes - SMAW, SAW, GTAW, MIG/MAG, FCAW and other
latest processes like PTAW , PAW & ESSC and so on, non-destructive testing like RT, UT, Cost Optimization
MPT, PT as well as fabrication of all types of materials including CS, SS, LAS, Al, Clad Steels,
Non-Ferrous materials and dissimilar materials as well Fabrication
Knowledge of Machining processes – Turning, Milling, Boring, Drilling, Deep hole drilling,
Planner, VMC etc. Quality Assurance & Control
Knowledge of forming processes – Rolling, Bending and other Presswork, experience in
developing customize dies and fixtures for the same. Team Building & Leadership
Unique blend of plant management, managerial & operational expertise with advanced
skills in strategic planning, international process implementations, commissioning, new set- PPAP Documentation
ups and resource allocation
Monitored production operations, process rationalization, manufacturing flow
harmonization and bottleneck & defect identification for improving operational efficiency
with enhanced customer orientation and focus Soft Skills
Proficiency in managing technically advanced, cost-efficient & state-of-the-art-production
systems to ensure top &bottom line profitability with skills in enhancing operational Motivator
effectiveness within preset cost, time & quality parameters
Providing leadership, coaching and training in lean thinking & lean production, variation Communicator
reduction, problem-solving & avoidance and people / team strategies
Change Agent

Education & Credentials Collaborator

MS - Industrial Production & Management from BITS, Pilani in 2000 Analytical

Bachelor of Mechanical Engineering from GEC, Raipur in 1995
Leader
Professional Experience

Mar’ 21 – Till Date: Everest Industries Limited

Working as Plant Head at Everest Industries Limited – Narmada Works, looking after all the
gamut of business in PEB (Pre engineered Building) related to manufacturing. Heading plant with
overall Fabrication capacity of 1800 MT / month with the target of increasing the same to 3000
MT/ month by 2023 -24, through overall process optimization in order to improve cost/ ton of
fabrication.
Jul’11 – Mar’ 21: Larsen & Toubro Ltd.
Growth Path / Deputations:
Jul’11– Dec’19: DGM – Production (Metallic), Maintenance & Safety, Ranoli Vadodara(Worked as
In-charge of production activities of facility with latest fabrication technology & customize
machining facility for handling SS and other exotic materials with annual turnover of more than
275 Cr & increasing Y-o-Y)
Jan’20 – Present: DGM – HTE Product Group (HE-IC) Hazira Surat
Jan’11 –Jun’11: ISGEC Yamunanagar
Assistant General Manager(Active Member of the team for U, U2, ISO, OHSAS and so on)

Jul’05 – Jan’11: Larsen & Toubro Ltd. (HED) Ranoli Vadodara

Project Manager

Apr’97 – Jun’05: Grasim India Ltd., NAGDA

Assistant Manager(Supervised fabrication of equipment’s for equipment’s for Viscose,
Auxiliary,CS2 Plant, ETP, Spinning and so on)

Mar’96 – Mar’97: Kinetic Honda Motors Ltd., Pithampur (M P)

Production Engineer

Key Result Areas:

Planning, organizing, directing, & controlling manufacturing operations through lean initiatives & business excellence philosophy
Working as In-charge of production activities for fabrication of Equipment’s like Waste Heat Boilers, Steam Drums, CG Boilers, RG
Boilers, Carbamate condensers, Urea Strippers, Methanol convers & Various Heat Exchangers
Steering Proposal Planning for marketing inputs on Technical feasibility, process improvement to reduce operation cost and time
Leading a team of 25 Staff members in various capacities with more than 15 Contractors with overall manpower of 650
Conceptualizing various innovative solutions to avoid repetitive failure & other problems that adversely affect process operations
including capacity, quality, cost & regulatory compliance issues
Facilitating Continual Benchmarking for subsequent attainment of achieving Zero Bad (Breakdown, Accident & Defect) in product as
well as in process across the organization
Establishing Quality Management Systems across various processes to reduce rejection levels and ensure high quality standards at
all the stages of production
Checking 100% implementation of process conditions for batch as per BPRs
Participating in selection & executions of projects
Key contributor for developing product portfolio in order to implement standardization, Maintain cost competitiveness and
improving margins
Emerging Innovative solution to resolve Technical and Capacity hurdles to convert Enquiry to Order
Ensuring the encourage culture of quality compliance and open communication that supports all employees to raise quality
concerns or suggest improvements
Designing manufacturing processes for dramatic improvements & other external strategic demands; identifying capacity limitation,
bottlenecks and process problems for taking corrective action
Implementing the preventive & predictive maintenance schedules for improving the overall reliability and safety of plant equipment
Coordinating with the clients for approval of drawings, technical documents, seeking technical clarification, progress reviews,
milestone payments, dispatches, site activities and so on
Liaising with internal &third party inspection agencies likes ASME, LRS, BV, EIL, PDIL, and so on
Providing periodical production reports to Management giving details of shortage if any in material availability
Identifying potential bottlenecks and deviations and implementing corrective actions to ensure that production targets are met
within stipulated time and budget constraints
Preparing quality / production procedures, work instructions and visual instruction to carry testing of product or part
Developing, managing and monitoring the performance of multi-skilled workforce and conceptualizing need-based training
programs for performing maintenance/production operations

Highlights:
Engaged in development of new technologies like Auto TIG, PTAW Resistance arc welding & many low-cost automation
Played an important role in approval of shop to many of the process licensors like Shell, Chevron, Axens, KBR, Emtrol Buell and so
on, for manufacturing of proprietary internals
Executed Site activities at IOCL, BPCL, SRF, MRPL and so on
Managed every year Bonus &Long Term Settlement, recognized as member of team negotiating with union & lead the union
towards “No Negotiation Settlement” in 2014 & 2018
Ensured compliance of system requirements for ISO, OHSAS, ISMS, U, U2 & N Stamp
Developed STM & DTM for shop floor activity
Worked as:
 o Member of Committee for initiation & institutionalization of Group Performance Award scheme
o Member of Team for IMEA & GMEA Award
Acknowledged as Champion of teams for Energy & Water conservation, WMS & TPM
Served as Chairman for Safety committee

Major Projects
Manufacturing of 17 Nos. Heat Exchangers for Bechtel
After cooler for wind tunnel project of VSSC
Four number Helix Exchanger for IOCL Panipat Naptha Cracker Project
Regeneration Tower with critical profile wire screen internals used in CCR Platforming for HPCL Mahul, HPCL Vizag, BORL, Technip &
IOCL Vadodara
Monel cladded drum tube sheet type, monel tube heat exchanger for IOCL Panipat under EIL
Heat Exchangers weighing 140 MT, 220 MT & 275 MT for Chinese refineries like petrochina&Sinopac
Screw Plug Exchangers for IOCL Vadodara
Classified Project for Indian Navy
Fresh Sub assembly Transfer Chamber for shifting nuclear fuel for Bhavini under NPCIL and so o
Reactor Internals for various process licensors like Axens , Exxon, UOP, CB &I etc.
Ammonia Converter Baskets for KBR
Regenerator cyclone for Emtrol Buell & KBR
Various equipment’s for Reliance J3 Project
Dry Shielded Canisters for Transnuclear
Pressure vessels for JGC, Sasol, IOCL and so on
Steam Generator for BARC

Personal Details
Date of Birth:7th January 1972
Languages Known:English, Hindi, Marathi
Address:C 187 San Tropez Madrid County in front of Ashapura temple Bhaili Vadodara, Gujarat
Current CTC: 32.8 LPA (26.3L + 6.5L) Fixed + Variable