Gali Eswar Rao

Steelmaking operations professional with 23+ years of experience across integrated and mini-mill steel plants, covering EAF/CONARC, hot-metal processing, LMF/LRF, RH/VD, CCM/CSP and slab/billet casting. Currently DGM – SMP2 Operations at AMNS India, responsible for integrated SMS production and safety across 200 t Conarc furnaces, HMPS, LMF, RH/TOB, CSP and slab caster operations. Strong background in shift leadership, steel grade planning, productivity, process optimization, quality, cost/consumption control, WCM/5S, RCA and greenfield project commissioning.

Experienced in critical grade of steel production and Process of HSLA, EDD, IF, Transformer, Line-pipe, Automotive and X60/X80 grades.

DGM, SMP2 Operations at AMNS India (2025 – Present)

Overall responsibility for Conarc furnace, HMPS, LRF, RH/TOB, CSP caster and slab caster operations, production and safety. Plant configuration handled: 4 × 200 t EAF/Converter (Conarc), 2 HMPS stations, 7 LMFs, 3 CSP casters and 1 slab caster.

• Lead cross-functional coordination among Production, Process, Quality, Maintenance and other shop-floor functions to maintain safe and stable production.
• Drive shift performance through grade/sequence planning, process discipline, breakdown contingency, manpower deployment and production recovery.

Senior Manager, SMP2 Secondary Metallurgy at AMNS India (2022 – 2025)

Process/production leadership for LRF/VD/RH, consumption reconciliation, data analysis, 5S and WCM implementation.

Shift In-charge, SMP2 Operations at AMNS India (2016 – 2022)

LF–VD/RH–CCM route planning and complete shift control.

Section Head – Process (EAF/LRF) at Abul Khair Steel Melting Ltd. (2013 – 2016)

Greenfield/project commissioning and operation of 2 × 85 t EAF, LF and 6-strand billet caster. Involved in EAF and AC-LF erection, cold/hot commissioning, production start-up, machinery/layout inputs and manpower recruitment. Handled overall production aspects including planning, scheduling, throughput, quality, productivity, resource utilization and coordination with maintenance. Commissioning experience with 2 × 85 t EAF, 2 LF and 6-strand open billet caster configuration.

Manager – Secondary Metallurgy / Shift In-charge at Essar Steel India Ltd. (2004 – 2013)

4 × 150 t DC EAF, 4 × 150 t LF/VD/RH/TOB and 3 slab casters.

B.E. in Metallurgical Engineering – NIT Raipur (formerly GEC Raipur) (2004)

Diploma in Metallurgical Engineering – Government Polytechnic College, Durg (2001)