Welders should feel that their voices are heard and that their concerns are being addressed.

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Mr. Ashik Parmar, Director & Head of Essar Heavy Engineering Services (EHES) Ltd  

  1. Being the Director & Head of Essar Heavy Engineering Services (EHES) Ltd since Aug’22 onwards. How has been your journey so far?

I joined EHES LIMITED in Feb’18 as Operation Head. My job was making people accountable for delivering things on time, and making sure the clients requests did not go off budget. It was all about Excel and meetings experienced in conflict management and resolution. I believe that all the client requirement. I was also head of the project planning department of this organization. I have led several project teams, worked with several senior executives, and personally reported to the board. I am also experience I have gathered through the years put me in Head/CEO position.

2. How much of total experience do you have?

I have total experience of 30 years.

3. Talk about your field responsibilities in your current organization?

The primary responsibilities of a Director of Manufacturing include overseeing the production process, ensuring that all products are manufacturing operations are carried out in a safe and efficient manner. manufactured to the highest quality standards, and that all. In addition, the Director of Manufacturing is responsible for managing the manufacturing budget, and for ensuring that all manufacturing deadlines are met. Also responsible for organization P&L, Strategizing, Revenue, Sales and Cost Control. Main objective is to strive for all stake holders satisfaction through our performance.

4. What checks and balances do you use to make sure that you don’t make mistakes?

When I have a project to do, I do it mentally first…that means sitting down job. measurements, materials, what could not fit or go wrong, I go over it and visualizing everything you are going to need to complete the scenario I get the materials and lay out the project and check for fit and all and accumulate or source everything I could possibly need in any compatibility, maybe run some tests if anything is in doubt. This usually gives me confidence to proceed in an aggressive style. Close Monitoring, Weekly Project Review Meeting & Expediting is process to control and complete the order at the given time set by the client.

5. Can you share some of the interesting anecdotes of any project?

Our last project 3D assembly of ODC (Over Dimensional Consignment) derrick structure was done during June to September quarter which is the monsoon season. At that time we are totally depends on weather condition so day by day our schedules was getting changed due to uncertainty as the job was going on large open ground area but with all this obstacles though we were able to achieve the set targets.

6. The company caters to what type of manufacturing requirements in India and other countries?

EHES Limited shall strive to become most preferred manufacturer of Heavy Engineering Equipment for core industry sectors like Refinery, Petrochemicals, Energy, Fertilizers, Steel, Power, Defense, Nuclear and Infrastructure Sectors.

7. Could you brief us on some of the mega projects you worked upon? What challenges you faced and how did you manage to cope up?

One of our mega project was 3D assembly of derrick structure having 125 meter long and 24 meter span. We assembled that structure in 7 modules which is very difficult task for our team.

In this project as a manufacturing director, I worked with a team of engineers to create a task possible for our company. We started by researching that what challenges and safety issues that will arise and then brainstormed ideas to meets client expectation. After narrowing down our ideas, we created prototypes on paper and tested them with customers to get feedback on which ones they liked best. At last we got success for 3D ASSEMBLED MODULARIZED DERRICK STRUCTURE DISPATCHED from EHES LIMITED in NOV’2022 which was the first time in INDIA.

8. Could you brief us on your recent project? What is it all about and your role into the same?

Currently we are working on equipment fabrication for NTPC, JNK India, Tuaman, SMS Group, AGFIS etc. 

As the director in a manufacturing company, my role in new projects would involve various responsibilities and tasks. Here are some key aspects of my role: 

Project Planning: I would be responsible for overseeing the planning phase of new projects. This includes defining project objectives, scope, timeline, and resource allocation. I’ll work closely with other stakeholders to ensure alignment with business goals.

Resource Management: As a director, I’ll need to assess and allocate resources for new projects. This includes managing budgets, procuring necessary materials and equipment, and assigning personnel to project teams.

Team Leadership: I’ll play a crucial role in leading and managing project teams. This involves setting clear expectations, providing guidance and support, and fostering a collaborative and productive work environment.

I’ll be responsible for ensuring that the team members have the necessary skills and resources to complete their tasks effectively.

Risk Management: Identifying and mitigating risks is an essential part of project management. As the director, I’ll need to assess potential risks associated with new projects and develop strategies to minimize their impact. This may involve implementing safety measures, conducting risk assessments, and establishing contingency plans.

Stakeholder Communication: Effective communication is vital in project management. I’ll be responsible for maintaining regular communication with stakeholders, including clients, suppliers, and internal teams. Keeping them informed about project progress, addressing concerns, and managing expectations are crucial aspects of my role.

Quality Control: Ensuring the quality of deliverables is another important responsibility. I’ll need to establish quality control processes, monitor project activities, and conduct regular inspections to ensure that the final products meet the required standards.

Project Evaluation: Once a project is completed, I’ll oversee the evaluation process to assess its success and identify areas for improvement. Analysing project outcomes, gathering feedback from stakeholders, and documenting lessons learned will help refine future project management strategies.

Overall, as the director in a manufacturing company, my role is to provide strategic direction, oversee project execution, and ensure successful project outcomes while considering factors such as cost, quality, and timeliness.

9. What new engineering specialty skills have you developed during the past year?

Lean Manufacturing and Process Optimization: Recognizing the importance of efficiency and productivity in manufacturing, identifying and eliminating waste, streamlining production processes, and implementing continuous improvement initaiatives. This skill set enables to enhance productivity, reduce costs, and improve overall operational efficiency within manufacturing plants.

Industrial Automation and Control Systems: Automation plays a pivotal role in modern manufacturing plants, improving productivity, accuracy, and safety. To stay at the forefront of this technological evolution, developed expertise in industrial automation and control systems. Adapting designing and implementing automated processes, integrating robotic systems, and programming programmable logic controllers (PLCs). These skills enable to optimize production lines, minimize human error, and maximize output.

Quality Control and Six Siga Methodology: Quality control is paramount in manyfacturing to ensure that products meet or exceed customer expectations. To bloster skill set in this area. We can acquired proficiency in quality control processes, conduct staistical analysis, and employ root cause analysis to identify and rectify issues. With these skill, we contribute to improving product quality, reducing defects, and enhancing customer statisfication.

Supply Chain Management and Logistics: A well-organized and efficient supply chain is critical for the success of any manufacturing plant. To strengthen our knowledge in this domain, we have focused on supply chain management and logistics. We understand the intricacies of inventory management, demand forecasting, and logistics optimization. This expertise enables to coordinate the flow of materials, minimize inventory holding costs and ensure timely delivery of products within the manufacturing plant.

Health and Safety Compliance: Safety is of paramount importance in any manufacturing environment. We have developed a strong understanding of health and safety regulations and practices specific to manufacturing plants. We are well-versed in risk assessment, hazard identification, and implementing safety protocols. By prioritizing and promoting a safe work environment, I contribute to the well-being of employees and compliance with industry standards.

By continually advancing engineering specialty skills within the context of a manufacturing plant, we are well-prepared to address the evolving demands and advancements in this dynamic industry. These skills enable to optimize processes, enhance productivity, improve quality, and ensure the overall success of manufacturing plant operations.

10. Have you contributed to any cost savings for your company? Elaborate if any.

There are a number of strategies that employed to reduce manufacturing costs. Some of the most common include:

1. Reducing raw material costs: This can be done through negotiating better prices with suppliers, using cheaper or finding alternative sources of raw materials.

2. Reducing labor costs: This can be done by automating processes where possible, reducing overtime hours, or training employees to be more efficient.

3. Reducing overhead costs: This can be done by streamlining operations, eliminating unnecessary expenses, or renegotiating contracts with vendors.

4. Reducing production costs: This can be done by improving production efficiency, reducing waste, or finding ways to produce items at a lower cost.

11. What type of latest technology have you adopted into the successful completion of any project?

Here are some ways that can make a huge difference:

• Leverage historical project data to make better bids and plans for future projects
• View resource availability, skills, and other details to simplify allocation
• Quickly allocate and track budgets to stay on top of financials
• Track all projects through customizable dashboards and make more informed decisions
• Keep all stakeholders and team members informed of project status, progress and changes made in real time
• Capture all expenses with invoices for all projects in real time

12. Please elaborate on the welding activities focused in the company? What new advancements in welding are practiced?

In many applications, solid welded pinch rollers are in use, which have been hard-faced by welding on an iron based high wear resistant material. In the majority of cases, a crack-free hard facing is not possible. Initiated cracks can propagate and combine in or beneath the welded hard layer leading to large-scale spalling of the roll surface. Refurbishment of such failures requires complete removal of the hard facing, gouging off of detected cracks in the roller base material as well as rebuilding of the whole wear protection layer. This procedure generates high costs and technical risks. According to experience, any further refurbishment can cause an increase of crack depth in the base body, so that irreparable spalling cannot be excluded. Nevertheless, EHES LIMITED has expertise to repair hard faced pinch rollers repaired by welding several times before they have to be scrapped.

13. What is the welder’s strength in EHES?

Total welders strength in EHES is 30. All are qualified in different welding processes like SMAW, GTAW, MIG in all position.

14. What are your efforts towards skill development of your welders?

There are a number of ways to manage and motivate welders in the manufacturing department. One way is to ensure that there is clear and open communication between fabrication supervisors, field engineers and welders. Welders should feel that their voices are heard and that their concerns are being addressed. Additionally, managers should provide welders with opportunities to grow and develop within the company. This could include training and development programs, as well as opportunities for advancement. Furthermore, we create a positive work environment where welders feel valued and appreciated.

15. What according to you is required to boost the welding and fabrication industry in India? Is this industry on par with the international markets?

In India, welding contribution in GDP is very significant and in various ways – like Fabrication industries, supplementary tools, manpower engagement, fabrication equipment and supporting industries. In India, the welding industries are using out-dated or not-up-to-date technology and mostly of conventional welding processes like gas welding, arc welding and others. However, use of robots, automation, and technology and process improvements are rising significantly India has seen high foreign direct investment equity inflow in various manufacturing sectors of automobile outsourcing projects, process and power sectors, ship building and heavy equipment manufacturing industries. In India, many overseas companies have established their automotive manufacturing plants, which have seen a high demand and rise in the Indian Welding Market.

16. What are your expectations from the government for the upliftment of the welding and fabrication segment?

The ‘Make in India’ program is the huge thrust behind the changes in approach and attitude in the industries look-out, innovative ideas, going for new processes and investments in all the sectors of manufacturing industries. It is proposed that Government Of Gujarat introduce specialized incentive scheme for reducing the cost of doing business and improving the investment attractiveness to target focus sector investments into Gujarat.

17. Quality welding and appropriate certification is a must for any fabricator? Your say? Is this considered as an important factor by Indian fabricators today? Please elaborate.

Welding is undoubtedly the most crucial of components when it comes to structural integrity. If you think around, you will see that every significant fixture is joined through a process of heating, assembling, and cooling, most commonly known as welding. And as necessary as this procedure seems, it is not only complicated but also risky, which is why it requires skilled welders to do the task. This brings us to address the importance of the quality of welded structures as, ultimately, the entire framework depends on it.

18. ‘Safety at site’ is one of the key factors. What are your efforts towards safety?

Every fabrication company should be well familiar in the fabrication safety rules and regulations. We at EHES LIMITED always ensuring

1. Use of PPE’s
2. Keeping work area clean
3. Heavy lifting precautions
4. Proper site training
5. Safety program and culture
6. Environmental guidelines… etc

19. Your future plans?

My vision for the future of the company’s manufacturing department is to continue to grow and expand our production capabilities satisfaction. I would like to see us continue to invest in new technologies also believe that it is important to maintain a strong focus on safety in the while maintaining our high standards of quality and customer and processes that will help us increase our efficiency and productivity. workplace and to continually strive to improve our safety record.”