Tapas Kumar Das
Shift In-Charge – Operations
Hire this person
Send a job offer directly to this candidate
About
Operations & Logistics Leader with 19+ years of heavy industrial experience, including 14 years with Tata Steel Limited, leading 24×7 BF slag plant operations, railway & road dispatch, bulk material handling, weighbridge operations, WLS/control room operations, and multidisciplinary shift teams. Proven expertise in managing 350–360 KT/month BF slag dispatch, 58–62 railway rakes/month and 100+ road vehicles/day, with end-to-end ownership of rake placement, wagon loading/unloading, transhipment wagon unloading, weighment, yard operations and dispatch coordination. Strong technical-operational exposure to PLC/SCADA/HMI, Wagon Loading Systems, conveyors, weighfeeders, weighbridge, MCC/PCC, VFDs and equipment reliability, supported by hands-on experience in 30+ planned shutdowns and breakdown recovery.
Recognized for 190-minute record rake-loading TAT, critical railway emergency response, demurrage control and 1,000+ LTI-free days, with a leadership approach focused on safety, productivity, plant availability, operational continuity, cost control and continuous improvement.
Experience
Shift In-Charge – Operations | Junior Engineer-III (Personal Grade) - Tata Steel Limited - Jamshedpur
(2011-10 - 2025-08)
Industrial By-Product Management Division (IBMD) - Led 24×7 BF granulated slag plant operations covering material handling, storage, reclaiming, yard management and dispatch of 350–360 KT/month. Managed integrated rail & road dispatch operations including 58–62 railway rakes/month, transhipment wagon unloading and 50+ tipper trucks/shift.
- Led 24×7 BF granulated slag plant operations, covering material handling, storage, reclaiming, yard management and dispatch of 350–360 KT/month.
- Managed integrated rail & road dispatch operations, including 58–62 railway rakes/month, transhipment wagon unloading and 50+ tipper trucks/shift.
- Directed end-to-end rake placement, wagon positioning, WLS loading/unloading, weighment, documentation and dispatch coordination.
- Managed weighbridge operations for vehicle weighment, gross/tare weight verification, loading confirmation, dispatch documentation and material reconciliation.
- Monitored weighbridge transactions and vehicle movement, coordinating with production, yard, transport and commercial teams to ensure accurate and timely dispatch.
- Managed PLC/SCADA/HMI-based Wagon Loading Station and centralized control-room operations, monitoring conveyors, feeders, weighfeeders, transfer systems and automated loading equipment.
- Led multidisciplinary shift teams comprising operations, electrical/mechanical maintenance, contract manpower, railway/shunting teams and technical vendors.
- Coordinated Maintenance, Electrical, Instrumentation, Quality, Railway, Transport and Commercial functions to maintain uninterrupted material flow.
- Planned and executed 30+ major maintenance shutdowns, preventive maintenance and breakdown-recovery activities supporting equipment reliability and plant availability.
- Supported maintenance of motors, MCC/PCC, VFDs, conveyors, feeders, weighfeeders, weighbridge and control systems.
- Managed road dispatch, weighbridge, vehicle loading, queue management, yard inventory and dispatch documentation.
- Coordinated with the Quality Laboratory for BF slag moisture testing and customer-specific quality requirements.
- Enforced PTW, LOTO, SOP, risk assessment, PPE and contractor safety requirements, contributing to 1,000+ LTI-free days.
- Achieved 190-minute record railway rake-loading TAT, earning a Shabash Award through synchronized manpower, equipment and railway coordination.
- Safely intercepted and stopped 4 runaway sick railway wagons during a night shift after an upstream asset failure, preventing a catastrophic rail accident.
- Resolved a critical rake weighing track-switch/load-cell failure during peak monsoon season in night shift, restoring loading operations and eliminating heavy railway demurrage fines due to delays.
- Strengthened weighbridge–WLS–dispatch coordination, improving weight verification, material accounting and dispatch control.
- Improved loading efficiency through weighfeeders calibration, loading-trend monitoring and wagon packing optimization.
- Redesigned reclaim-hopper discharge chute, increasing conveyor throughput and eliminating recurring material spillage.
- Implemented automated dust suppression using mist cannons, improving dust control and workplace conditions.
- Implemented 5S/Model Workplace, Lean, TPM, Kaizen, RCA and DWM initiatives to improve productivity, reliability and housekeeping.
- Maintained 1,000+ LTI-free days through proactive risk assessment, contractor supervision and field safety audits.
- Served as Departmental Ethics Champion, supporting MBE, Speak Up, POSH and DARPAN initiatives.
Junior Manager – Service - Cummins India Limited – Distribution Business Unit (DBU) - Ranchi
(2010-11 - 2011-03)
- Provided technical support and maintenance for industrial diesel generator installations across Jharkhand and Bihar.
- Planned preventive maintenance activities and managed equipment breakdown response.
- Monitored equipment performance and coordinated spare parts planning.
Customer Support Engineer – Service - TIL Limited (Caterpillar Dealer) - Sahibabad
(2006-11 - 2010-10)
- Commissioned, maintained, and overhauled Caterpillar diesel generator sets.
- Diagnosed electrical and mechanical faults and carried out preventive maintenance.
- Worked on synchronization panels, control systems, Annual Maintenance Contracts (AMC), and Customer Support Agreements (CSA).
Education
Post Graduate Diploma - Environmental Management - Institute of Environmental Management Studies (IEMS) (2024)
Diploma - Electrical Engineering - Central Calcutta Polytechnic (2006)
