Prajesh Kumar Gaur

Reliability and maintenance leader with 20+ years experience in aluminium smelter operations including carbon plant, reduction and cast house. Expert in Reliability Centered Maintenance (RCM), Root Cause Failure Analysis (RCFA), FMEA, asset criticality and maintenance strategy deployment. Strong experience implementing Asset Optimization frameworks, improving plant availability and leading cross‑functional teams.

Lead – Asset Optimization & Reliability - Lizmontagens Aluminium Services India Pvt. Ltd. | Client: BALCO (Vedanta) - Korba, India

(2022-04)

• Implemented Asset Optimization framework across smelter operations.
• Achieved highest AO external audit score at BALCO site among Vedanta Group(FY23-FY26).
• Winner of Asset Optimization rolling trophy for three consecutive quarters (FY26).
• Improved reliability practices for Carbon plant /POT Line PTM cranes and Smelter equipments.

Reliability Engineer / Acting Maintenance Superintendent - Hillside Aluminium Smelter – BHP Billiton / South32 - Richards Bay, South Africa

(2009-05 - 2019-08)

• Led CAPEX reliability improvement projects in carbon plant and cast house.
• Executed Vibro Vacuum Unit upgrade with Solios France.
• Led hydraulic refurbishment and pneumatic conveying piping change‑out.
• Improved plant availability by 5–6% via maintenance optimization.

Carbon Plant Engineer - BALCO Vedanta - Korba, India

(2004-07 - 2009-04)

General Management Certification - IIM Raipur (2021)

B.E. - Mechanical - Govt Engineering College Ajmer, University of Rajasthan (2003)