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Dr. Md Uddin

PhD (CQU) M BUS (UWS) M MANUF (UNSW) B Sc (BUET) LSS GREEN BELT
Lecturer - Asset & Maintenance
School of Engineering and Technology
Melbourne
120 SPENCER ST - MEL 5.12
About Me

Dr Md Uddin is a lecturer in Asset and Maintenance Management in the School of Engineering and Technology (SET), Central Queensland University, Australia. Since 2016 he is serving CQUniversity in Mechanical Engineering (UG & PG) and Asset & Maintenance Management (PG) courses at a high level of integrity, dedication and enthusiasm towards his national and international student cohorts from diverse background of culture, race, religion, gender and profession.

He has more than 15 years of industry and academic experience in mechanical engineering, reliability engineering, asset & maintenance management, project management, operations management, engineering & manufacturing management and business improvement lean six sigma.

Before joining CQUniversity in 2016, he was working as a Specialist/Reliability Engineer in Rio Tinto, which is one of the world largest mining companies listed as FORTUNE 500 currently operating globally. He has an excellent track record of serving mining and metals, heavy haul railways and manufacturing industries nationally and internationally; along with experience in teaching as well as research through publications. He has sustained and ongoing achievements in the areas of mechanical engineering, asset and maintenance management best practice, implementation of optimised asset strategy, asset life cycle management and modelling, RAMS modelling in reliability engineering, strategic development in heavy haul railway asset management. He is serving a number of national and international conferences as committee member, track chair and industry chair (IEEE/CSDE 2019 Melbourne Australia, IEEE/CSDE 2020, Virtual). Currently, he is a member of Institute of Engineers Australia (MIEAust), Asset Management Council (AMC) Australia (which is a member of World Partners in Asset Management - WPiAM), Railway Technical Society of Australasia (RTSA).

He has a true passion to excel in creating an outstanding teaching and learning environment for engineering education specifically industry focused, which will create greater attraction to community in engineering and technology.

General
Background

He has completed his PhD from CQUniversity in 2016, Master of Business in Engineering Management from UWS in 2005, Master of Manufacturing Engineering from UNSW in 2004 and Bachelor of Science in Mechanical Engineering from Bangladesh University of Engineering and Technology (BUET) in 2002.

His PhD research was funded by CRC for Rail Innovation Australia and the topic was “Wayside Rail Curve Lubrication Placement Modelling for Australian Heavy Haul Lines”, where he proposed effective rail curve lubricator placement model based on optimisation of lubricator configurations, determination of best effective lubricants with optimal grease application rate in high and low rail gauge face location. As a highly successful project it concluded that the traditional old technology high rail gauge face lubrication in in heavy haul railway curves was completely ineffective to support business objectives and incurred outstanding Operational cost (OPEX) cost in Total Life Cycle. His research showed that instead of ineffective placement of lubricators in the curve, appropriate placement of lubricators in the tangent track with most suitable high performance grease, can successfully serve two rails at a significant distance at a target friction level and can save enormous cost from rail wheel replacement, rail wheel maintenance, operational and maintenance cost of lubrication systems in a geographically vast tract network. It was also showed that remote performance monitoring technology application in heavy railway rail curve lubrication can extensively reduce the operating and maintenance cost of lubricators with precise control of grease application and preventive and or predictive maintenance implementation.

Since July 2016 he is working as a Lecturer in Engineering in CQU in different capacity of responsibility. he jointly with others, has published numbers of journal and conference papers, 30+ industry reports to Australian Rail CRC and Rio Tinto. His PhD research outcomes has been adapted in standards in leading railway organisations in Australia and cited nationally and internationally.

He has completed significant number of teaching & learning (L&T) and professional industry trainings and development. He found that his strong industry experience in Asset and Maintenance Management, PAS-55, ISO55000, Dependability Management AS IEC60300, Reliability Engineering, Defect Elimination, Root Cause Analysis (RCA), Planned Maintenance Optimisation (PMO), Reliability Centred Maintenance (RCM), Failure Mode Effect and Criticality Analysis (FMECA), Lubrication & Tribology, Condition Monitoring, Engineering Change Management, SAP Master Data Management, Shutdown and Turnaround Management, Maintenance Audit & Organisation, Maintenance Materials, Maintenance Leadership, RAMS (Reliability, Maintainability, Availability and Safety) Engineering, Asset Life Cycle Analysis, Compliance Management, Contractor Management, Design and Project Management, Continuous Improvement prepared him as an excellent professional engineer who is strongly capable to cater industry focused quality engineering education.

His highly developed expertise and experience have built his confidence, strength and interest in teaching Mechanical Engineering, Asset and Maintenance Management, Project Management in engineering education

Universities Studied At

§ Doctor of Philosophy completed in 2016

Centre for Railway Engineering (CRE), School of Engineering and Technology, CQ University

Doctoral Thesis: Development of Wayside Rail Curve Lubrication Model for Australian Heavy Haul Lines

§ Master of Business in Engineering Management completed in 2005

School of Engineering, Western Sydney University

§ Master of Engineering in Manufacturing Engineering & Management completed in 2004

School of Mechanical & manufacturing Engineering, The University of New South Wales

§ Bachelor of Science in Mechanical Engineering completed in 2002

Bangladesh University of Engineering & Technology, Dhaka Bangladesh

Universities Worked At

CQUniversity Australia

Awards

§ Received Certificate of Appreciation for being TRACK CHAIR at IEEE CSDE/i-COSTE 2019, 9 – 11 December Marriot Melbourne Australia

§ Certification of Completion of Module Integrity and Compliance Rio Tinto, completed on 17 August 2015

§ Certificate of Attendance two days workshop on Root Cause Analysis funded by Rio Tinto and certified by RCA RT (Round table) SIRT.

§ Certificate of Completion EasyPC Training Excel Intermediate funded by Rio Tinto 9 May 2012

§ Completion of Certification of two days course on Pumping Fundamentals and Advanced Pumping, training provider Strategic Achievement

§ Certificate of Completion of the three days Asset Management Practitioner Program (Introduction to Asset Management Strategies and Tactics, Asset management Frame Work- Identity and Plan Work, Asset Management Framework – Execute and Complete Work) by Rio Tinto

§ Certificate of Completion of three days Course Asset management Introduction to Reliability (Reliability Concepts, Tactics Development and Reliability Modelling) in Asset Performance Management (APM) previously known as Meridium

§ Full PhD scholarship in Australian Rail CRC (2009-2012)

§ Technical Scholarship in total 8 semesters in Undergraduate Studies, (1995 -2002)

§ Awarded star marks in HSC (1994) and SSC(1992)

§ Merit Scholarship (1986 - 1992)

Media Citations

Google Scholar Citation History

Cited by



Scopus h-index 1

All Since 2015
Citations 28 16
h-index 3 2
i10-index 1 1

Previous teaching

Lecturer in Engineering Program (Feb 2018 – Feb2019)

Key Responsibilities:

§ Prepare and deliver lectures, tutorials and laboratory practicals, undertaking assessments and marking for undergraduate engineering units

§ Provide extensive support to Project based Learning (PBL) units for all Gladstone campus students and marking thesis for final year undergraduate students and GECon Final Year Conference presentations

§ Liaise with relevant academic and professional staff as required with the School of Engineering and Technology

§ Collaborate with colleagues and other academics and students to come up with concepts of joint project/research

§ Continue to maintain ongoing local industry relationships, professional affiliation with professional bodies and local community in Gladstone

Associate Lecturer Mechanical Engineering Program (June 2017 – Feb 2018)

Key Responsibilities:

§ Prepare and deliver lectures, tutorials and laboratory practicals, undertaking assessments and marking for undergraduate engineering units

§ Provide extensive support to Project based Learning (PBL) units for all Gladstone campus students and marking thesis for final year undergraduate students and GECon Final Year Conference presentations

§ Liaise with relevant academic and professional staff as required with the School of Engineering and Technology

§ Collaborate with colleagues and other academics and students to come up with concepts of joint project/research

§ Continue to maintain ongoing local industry relationships, professional affiliation with professional bodies and local community in Gladstone

§ Support required administrative function required for the units I involved and attending all relevant school/organisational meetings, workshops, local showcases and engagement activities for young students and engineers.

Sessional Academic Engineering Program (June 2016 – June 2017)

Key Responsibilities:

§ Prepare and deliver lectures, tutorials and laboratory practicals, undertaking assessments and marking for undergraduate engineering units

§ Provide extensive support to Project based Learning (PBL) units for all Gladstone campus students and marking thesis for final year undergraduate students and GECon Final Year Conference presentations

§ Liaise with relevant academic and professional staff as required with the School of Engineering and Technology

§ Collaborate with colleagues and other academics and students to come up with concepts of joint project/research

§ Continue to maintain ongoing local industry relationships, professional affiliation with professional bodies and local community in Gladstone

§ Support required administrative function required for the units I involved and attending all relevant school/organisational meetings, workshops, local showcases and engagement activities for young students and engineers.

Sessional Academic Undergraduate Engineering Program (Feb 2010 – Oct 2011)

Key Responsibilities:

§ Support undergraduate student cohorts for Gladstone and other Campuses as a local lecturer, tutor and marker

§ Ensure strong student satisfaction for effective delivery of laboratory activities and Tutorials

§ Prepare, assess and mark the assessments, and provide appropriate, effective and timely detailed feedback to students

§ Conduct Unit Moderation and development of Unit Materials

Professional Experience

Reliability Engineer Rio Tinto Aluminium Ltd (Mar 2015 – Jun 2016)

Hydrate Operations, Yarwun Alumina Refinery Gladstone QLD

Key Achievements:

§ Successfully delivered area Top 10 reliability engineering projects at any time in the role.

§ Lead in Yarwun Rapid Business Transformation Program and secured cost savings of $6.5 million by implementation of coarse seed circuit turnaround plan as a long-term maintenance strategy.

§ Optimised over 1300 predictive and preventive asset maintenance strategies which resulted over 30% reduction in routine maintenance cost per annum and 60% reduction of unplanned failure.

§ Completed hydrate filter circuit equipment hierarchy and criticality assessment by conducting SAP asset data analysis and FMECA. Resulted highest component data accuracy and specifications.

§ Successfully completed continuous Improvement project of “Hydrate Filtration Central lubrication System” and resulted savings over $250K per annum due to optimised grease consumption.

§ Ensured defect elimination of vacuum pumps and drives as a result of data analysis, RCA, Reliability Centered Design and optimised maintenance strategy. Estimated savings $2.00 million in annual maintenance cost, $5.00 million in yearly throughput and minimise system downtime to nil.

§ Became Certified Lean Six Sigma Green Belt and completed Business Improvement projects valued up to $3.5 million as cost savings and improved throughput.

Key Responsibilities:

§ Drive “Zero Harm” through investigation, reporting, trainings and compliance management

§ Facilitate and implement outcomes from reliability review, tool box meetings, RCA, FMECA, RCM, PMO, OEE sessions

§ Data driven decision making and successful implementation of Reliability improvement initiatives

§ Monitor, analyse and quantify reliability cost savings, increased production and equipment life cycle costs to contribute in strategic reliability planning for business

§ Provide assistance to area Maintenance, Project & Engineering teams with processes and tools for effective critical spares analysis, PM Optimisation, condition monitoring etc.

§ Implement Lean Six Sigma DMAIC methodology in Business Improvement project and reduce waste

§ Review and challenge current equipment maintenance strategies, shutdown strategies and recommend and implement optimised ones

§ Review asset integrity and recommend data driven asset shutdown/turnaround plan in Asset Criticality Review & Analysis (ACRA) budgeting sessions.

§ Liaison with various stakeholders and holistic engagement with key contractors, suppliers and vendors to ensure organisational, operational and reliability excellence

Specialist Reliability Engineer (Acting) Rio Tinto Aluminium Ltd (Oct 2012 – Jan 2013)

Whiteside Operations, Yarwun Alumina Refinery Gladstone QLD

Key Achievements:

§ Winner of the business case of long term asset refurbishment strategy (final cost of $680K) against new asset requisition (4000K) for Yarwun Refinery 1 & 2 vacuum pump fleets. Total cost avoidance of 3.32M for new asset acquisition and significant loss avoidance in throughput for next 10 years.

§ Yarwun 1 Hydrate Filter fleet reliability availability and performance improvement project generate filter drive’s service life more than 10 times and estimated saving of 500K in maintenance cost and 80% reduction in production loss due to unavailability (Green Belt Project).

§ Yarwun 1 and Yarwun 2 Heat Exchanger’s defect elimination (wear reduction) by differential pressure equipment life improvement from 3 months to 4+ years, annual cost savings over $500K.

Key Responsibilities:

§ Enforce Equipment Criticality Analysis, Risk Mitigation, Rotables Spares for long-term savings

§ Mange Trials and Change Management appropriately to ensure process and personnel safety

§ Statistical analysis and reporting of reliability and maintenance data from SAP/Uniformance, manage improvement activities, review, develop and report reliability related KPIs

§ Support and mentor Area Reliability and Maintenance Engineers to ensure success of projects

Reliability Engineer Rio Tinto Aluminium Ltd (Feb 2012 – Mar 2015)

Whiteside Operations, Yarwun Alumina Refinery Gladstone QLD

Key Achievements:

§ Studied and analyzed existing operations and maintenance (O&M) practice and established cost effective planned maintenance strategy for central hydrate SPL extraction and vacuum system. As a result estimated annual power savings of over $270K, Spent Pregnant Liquor (SPL) and production throughput increased over 10%.

§ Developed cost effective long term maintenance strategy for cooling towers and eliminated unplanned breakdown and improved service life from 3 years to vendor expectation of 15+ years.

§ Improved maintenance strategy and service life of flexible joints/bellows from less than a year to 5+ years by ‘fit for the purpose’ material selection. Achieved availability 100%.

§ Improved Refinery 2 Hydrate plant failure frequency by facilitating and implementing RCA actions (52 actions). It resulted elimination of unplanned trips and avoidance of 3000+ Tonnes production loss per day.

§ Improved Hydrate and Calcination area blow air asset fleet’s (AERZEN GM240S) service life from less than 1000 to 15000 operating hours by implementing optimum system design, implementing FMECA and optimised fleet maintenance strategy resulted annual cost saving more than $1.00 M.

§ Outstanding improvement in Precipitation tanks/drive reliability by robust ‘fit for the purpose’ equipment acquisition, effective maintenance strategy and condition monitoring regime implementation. MTBF improved from one month to 5+ years, maintenance cost savings over +170K annum and Production loss avoidance over million dollars per annum.

Key Responsibilities:

§ Analyse plant data, alumina refining process and plant capabilities to recommend long-term improvement and cost saving

§ Facilitate Root Cause Analysis (RCA) and manage the completion of associated actions

§ Support maintenance team in planning, scoping and resourcing during unplanned plant outage and provide technical support and effective change management

§ Ensure asset integrity and reliability by continuous improvement of processes and equipments through technical leadership and structured process of investigation

§ Ensure strong asset utilisation and optimisation through long term asset strategy implementation, minimising O&M (Operations & Maintenance) cost and ongoing production loss

§ Recommend high potential capital and operational projects which will provide exceptional high payback for business and increase plant reliability at ultimate level

Engineering Researcher in PhD CQ University (Mar 2009 – May 2012)

Heavy Haul Railway Projects, Centre for Railway Engineering (CRE)

Key Achievements:

§ Developed & delivered effective lubrication and maintenance best practice for Australian heavy haul railways and contributed substantially in a Billion dollars issue of Australian national economy.

§ Research outcomes had been adapted by state and federal railway organizations in Australia as rail industry standards.

§ Developed detailed methodology for rail curve lubrication field testing, data collection, data analysis and data validation which was validated by Rail CRC Australia.

§ Developed and implemented ‘Dual Benefit’ cost modelling against ‘Dual Loss’ cost model.

§ Develop Lubrication Modelling, Economic and LCC Modelling for heavy haul railways.

§ Published 20+ high quality industry reports and publications in Journals and Conferences.

Key Responsibilities:

§ Study and analyse the reliability, performance and defects data of rolling stock and rail track assets

§ Investigate and report on network-wide rail asset performance and compliance with safety standards, trends in rail defects and failure

§ Research, develop and promote emerging technologies and equipment, as well as procedures and standards relating to rail technology and maintenance, including rail metallurgical issues, tribological aspects

§ Contractor management, procurement, delivery and First Article Inspection (FAI) of equipment

§ Coordinate international and Australian suppliers for technical communication in after-sales services, testing, commissioning and troubleshooting

§ Review the performance of Rolling Stock (wheel, wagon, bogie and locomotive) assets and contribute to the development of cost effective improvements to asset safety and reliability

§ Provide stakeholder interface with all internal and external stakeholders including suppliers, Engineers, Project Managers, International Expert Collaborators

§ Generate RBDs, BOM’s and prototype test plan and facilitate RCA, RCM, FMECA, DE sessions

§ Develop rail curve lubrication best practice for Australian heavy haul railways

Asset Protection Officer Secure Corp Australia (Jun 2007-Dec 2008)

Sydney Operations NSW

Key Achievements:

§ Study and analyse asset conditions and data and improved on site asset loss by 10%.

§ Avoid frequency of vandalism by 5% through critical investigations and effective control measures.

§ Maintained effective stakeholders’ engagement through effective communication, interpersonal skills, and problem solving and stakeholder management.

Production in Charge Finished Products Pty Ltd (Sep 2005-Apr 2007)

Punchbowl NSW

Key Achievements:

§ Manage metal coating operations supervise production lines and ensure product quality.

§ Continuous quality improvement, reduce waste and production cost by 15% per annum.

§ Investigate and report production and process failure and improve 30% increment in annual rate.

Professional Memberships

§ Institute of Engineers Australia (IEAust)

§ Asset Management Council (AMC) of Australia

§ Railway Technical Society of Australia (RTSA)

Responsibilities

  • Industry Engagement and collaboration
  • Share and update on Knowledge and experience
  • Present and publish scholarly latest activities and research  

Professional Interests

§ Asset Management in Mining, Industrial, Infrastructure, Utilities and health Sector

§ Maintenance Best Practice and Optimisation

§ Mining and Metal processing Operations and Maintenance

§ Reliability Engineering and RAMS Modelling

§ Rail Industry, Transportations and Safety and Risk Management

§ Tribology (Friction and Wear and Life), Rolling Contact Fatigue,

§ Sustainability Enhancement and Asset Management in Renewable Energy Sector

§ Applied Mechanical and Contemporary Manufacturing Engineering challenges

§ Industrial Process, Business Improvement, and Lean Six Sigma

§ Student success and challenges in online and distance engineering education

Key Achievements

Key Achievements in Current Academic Role:

Research

§ Number of Research Student in CV82 and CC18 Completed: 3 in CV 82, 1 in CC18

§ Currently Active Research Student IN CV82 and CC18: 5 (3 CV 82, 2 CC18)

§ Potential Research Student in CC18: 5

§ Reviewed Confirmation of Candidature (CoC) report for one RHD Masters Candidate

Publications

§ Published Conference Paper: Analysis of Pressure Gauge Reliability in Highly Caustic Alumina Precipitation Process – A Case Study. Authors: Md Gyas Uddin, Salahuddin Azad, Subhash Sharma. Presented in IEEE I-COSTE 2019, 9 – 11 December 2019, Marriott Hotel, Melbourne Australia. Available from https://ieeexplore.ieee.org/document/9162405

§ Manuscript submitted Journal Paper: Life Cycle Cost Analysis for Comparative Study and Asset Acquisition Decision Making in Wayside Lubrication Techniques (Manuscript submitted). Authors: Md Gyas Uddin, Mohammad Golam Rasul, Subhash Sharma

§ Manuscript Ready for Submission

§ Journal Paper: Holistic Approach of Strategic Modelling of Rail Curve Lubrication for an Entire Heavy Haul Network. Authors: Md Gyas Uddin, Mohammad Golam Rasul, Subhash Sharma

§ Journal Paper: Development of an Optimal Asset Replacement Model Based on Life Cycle Costing and Business Plan Requirements. Authors: Greg Mckay, Md Gyas Uddin, Subhash Sharma

§ Journal paper: Using Pattern Recognition to Turn Bad Data into Good Data for Improved Outcomes in Reliability Investigation of Utility industry Asset Failure. Authors: Philip Sage, Md Gyas Uddin, Subhash Sharma

§ Manuscript under Preparation for Submission

§ Journal Paper: Study and Analysis of Reliability and Cost in Alternative Asset Solutions with IT enabled enhanced remote condition monitoring Techniques, Reliability Engineering and System Safety. Authors: Md Gyas Uddin, Subhash Sharma, Mohammad Golam Rasul, Ahsan Morshed

§ Journal Paper: Cost Effective Life Cycle Management of Wayside Plants for Railways by Enhanced Monitoring of Operating Conditions via Wireless Technology, Authors: Md Gyas Uddin, Subhash Sharma, Mohammad Golam Rasul

§ Development of Grease Transport Mechanism Model for Rail Curve Lubrication in Heavy Haul Railway Application. Authors: Md Gyas Uddin, Subhash Sharma, Mohammad Golam Rasul

Submitted Grants applications

§ Study of flexible teaching model in ICT higher education in Australian context (ALTA small grants scheme 2020). Total Budget Estimate: $10,000.00. Team Members (Ahsan Morshed, Salahuddin Azad, Md Gyas Uddin, Md Rahat Hossain, Fariza Sabrina, Marilyn Wells, Saleh Wasimi, Colin Beer). Role: Md Gyas Uddin, Associate Investigator (Risk Management Model Development). Funding Organisation: ACDICT (Australian Council of Deans of Information & Communication Technology). Submission Deadline: 21 February 2020. Outcome: Not successful

Efforts of Potential Grants Applications EOI IN Macquarie SmartCrete CRC fund

§ Since June 2019, I engaged with CE (Civil Engineering) team and CQU Research Partnerships, Research Division Manager Josh Ariens, to develop future potential grant proposal or expression of interest for Macquarie SmartCrete CRC fund. I proposed three potential research topics/projects in asset management predictions/modelling for infrastructure asset as follows:

§ Decision making in risk management for concrete infrastructure based on Triple action of RCA, RCM and FMECA methodology Effective modelling of condition monitoring in least accessible and or high-risk access concrete infrastructure

§ Holistic Asset Management Approach to long term cost/benefit analysis based on alternative solutions and decision making/prediction of entire Life Cycle Cost

§ Investigation on Remote Performance Monitoring Technology/sensors and decision making to deploy the appropriate one based on RAMS (Reliability, Availability, Maintainability and Safety) approach

Completed Scholarly Activities

§ Capacity Building Course Foundations of Learning and Teaching (FoLT) training in 23 October 2019 and join SET retreat program in Brisbane to engage with CQU engineering colleagues and SoLT sharing and learning

§ Capacity Building Course LTS Academic Information Sessions (Scholarly Activity session, Academic Integrity Session) MEL 11 February 2020

§ Microsoft Collaborative Technologies Workshops Day 1 and Day 2 on 6 & 7 February 2020

§ Academic Integrity for staff training 5 Modules completed 14 Feb 2020

§ Teaching Space Videoconference Training 17 Feb 2020

§ Attended virtual Learning & Technology Conference in CQU in Dec 2019

§ Attended academic misconduct: perspectives of sessional staff sessions in CQU 04 Dec 2019

§ Academic Integrity in Action – Dealing with an Academic Integrity Incident – Part 1: Detect and Investigate Training 28 July 2020

§ Academic Integrity in Action – Turnitin Explained Training 30 July 2020

§ DataSmart Course Detailed Dashboard

§ DataSmart Unit Detailed Dashboard

§ DataSmart Course HE Weekly Progressive Student Unit Enrolment Dashboard 19 July 2019

§ DataSmart CQUniversity Dashboard 19 July 2019

§ DataSmart Course Unit Evaluation Dashboard 11 October 2019

§ CQURenew Showcase 15 July 2020

§ CQU Engineering Showcase GECon Conference Since 2016

§ CC18 Master of Asset and Maintenance Management is now a separate stream in Masters ENRP20001 Research project Planning and 20003 Research project Implementation units. Asset and Maintenance Management Discipline will organise separate Presentation Session for student thesis presentation. Relevant industry experts will mark the thesis presentations, review and mark the thesis.

Our Communities

Engagement/Leadership

§ Industry Forum Co-Chair at IEEE CSDE/i-COSTE 2019, 9 – 11 December, Melbourne, Australia

§ Track Chair at IEEE CSDE/i-COSTE 2019, 9 – 11 December, Melbourne, Australia

§ Industry and Local Arrangement Chair at IEEE CSDE/i-COSTE 2020, 16 – 18 December, Gold Coast, Australia (Due to COVID-19 restriction moved to Virtual Conference)

§ Awards:

§ Received Certificate of Appreciation for being TRACK CHAIR at IEEE CSDE/i-COSTE 2019, 9 – 11 December Marriot Melbourne Australia

Partnerships / MoU’s

§ Partnership/collaboration with Aanton Parr Australia and New Zealand seeking opportunity to work together in tribology and wear research and investigation

§ MoU with BORAL Australia

§ SEW EURODRIVE Australia, world leading Gear drive manufacturer

§ VIC Government health and transport Asset management

§ Bombardier Australia, railway asset management and maintenance

Our Reputation:

§ Accreditation activities / status (internal & external)

§ 5 Years Programs Review (internal) - Asset and Maintenance Management

§ I played a key role in preparation, collating data and information from CQU, national and international sources for the site visit session report development

§ Site visit completed on 5 February 2020 and recommendations provided by the review panels. A &MM TEAM is currently working on addressing and implementation of the recommendations.

§ Review and proposed content update for units in Five years Review program for Asset and Maintenance Management courses.

§ In “Five Years Course Review of Asset and Maintenance Management” a national and international search was conducted for currently offered degree qualifications, competency-based industry training and micro-credentials in asset and maintenance management, infrastructure management and facilities management to benchmark our Asset and Maintenance Management course and degrees.

§ I had significantly contributed CQU’s current asset and maintenance management programs to ensure we are always trying to be at the leading edge compare to our competitors.

Key Achievements in Industry Experience:

§ Successfully delivered area Top 10 reliability engineering projects at any time in the role.

§ He Led as one of key Area and Projects Lead for Yarwun Refinery’s White side during Rapid Business Transformation Program in 2015/2016. He had delivered three of the major Lean Six Sigma Business Improvement Green Belt projects with estimated value generation of $6.5 million.

§ He had improved and optimised over 1300 predictive and preventive asset maintenance tactics which resulted consolidated asset maintenance strategies with over 30% reduction in maintenance and inspection cost per annum and approximately 60% reduction of unplanned failure.

§ Successfully completed continuous Improvement project of “Hydrate Filtration Central lubrication System” and resulted savings over $250K per annum due to optimised grease consumption and improved filter hydrate reliability and availability.

§ Competed defect elimination project for vacuum pumps and drives with vigorous data analysis, marathon RCA, Reliability Centred Design and optimised maintenance strategy. Estimated savings $2.00 million in annual maintenance cost, $5.00 million in yearly throughput and minimise system downtime.

§ Completed Lean Six Sigma Green Belt trainings and completed two Business Improvement projects valued up to $3.5 million. As a results he became Certified Lean Six Sigma Green Belt in Rio Tinto. Due to his dedication and success as a Green Belt he was nominated for Lean Six Sigma Black Belt in 2014.

§ Winner of the business case of long-term asset refurbishment strategy (final cost of $680K) decision making against new asset acquisition proposal of $4.00 million for Yarwun Refinery Stage 1 & Stage 2 vacuum pump fleets. Total cost avoidance of $3.32 million for new asset acquisition and significant loss avoidance in throughput for next 10 years.

§ Yarwun 1 Hydrate Filter fleet reliability availability and performance improvement project generate filter drive’s service life more than 10 times and estimated saving of 500K in maintenance cost and 80% reduction in production loss due to unavailability (Green Belt Project).

§ Yarwun 1 and Yarwun 2 Heat Exchanger’s defect elimination (wear reduction) by differential pressure equipment life improvement from 3 months to 4+ years, annual cost savings over $500K.

§ Investigated and analysed existing operations and maintenance (O&M) practice to established cost effective planned maintenance strategy for central hydrate area SPENT Pregnant Liquor extraction and vacuum system. As a result, estimated annual power savings of over $270K per annum from 8 of the vacuum pump units each driven by 680 KW motor, Spent Pregnant Liquor (SPL) extraction and production throughput increased over 10%.

§ Developed cost effective long term maintenance strategy and reliability centred redesign of critical components and instrumentation for Stage 1 hydrate area cooling towers improved MTBF for components and enhanced service life from 3 years to vendor expectation of 15+ years.

§ Improved maintenance strategy and service life of flexible joints/bellows from less than a year to 5+ years by ‘fit for the purpose’ material selection. Achieved availability 100%.

§ Improved Refinery’s Stage 2 Hydrate plant failure frequency by facilitating and implementing Defect Elimination RCA actions (52 actions). Numbers of projects were developed from 52 RCA actions and all of them were implemented as a mega RCA/Defect Elimination project. It resulted elimination of unplanned trips and avoidance of 3000+ Tonnes ($150/tonne) production loss per day.

§ Improved Hydrate and Calcination area blow air system asset fleet’s (AERZEN GM240S air blowers) service life from less than 1000 operating hours to 15000 operating hours. It was done by implementing optimum system design, implementing FMECA and optimised fleet maintenance strategy which resulted in annual maintenance and asset replacement cost saving of more than $1.00 M along with avoidance of estimated lost production opportunity of 3000 tonnes per annum.

§ Outstanding improvement in Precipitation tanks/drive reliability by design out the failure with robust ‘fit for the purpose’ equipment acquisition, effective maintenance strategy and condition monitoring regime implementation. MTBF improved from one month to 5+ years, maintenance cost savings over +170K annum and Production loss avoidance over million dollars per annum.

Key Achievements in PhD:

§ Study and collaboration with national and international collaborators from North American heavy haul railways and technology suppliers. Attended and published research outcomes in world largest railway conferences and visited facilities.

§ Developed & delivered effective lubrication and maintenance best practice for Australian heavy haul railways and contributed substantially in a Billion dollars issue of Australian national economy.

§ Research outcomes had been adapted in rail industry standards by railway asset owners in Australia.

§ Developed detailed methodology for rail curve lubrication field testing, data collection, data analysis and data validation which was validated by Rail CRC Australia it was one of the detailed investigations in rail curve lubrication practice around the globe.

§ Developed and implemented ‘Dual Benefit’ cost modelling against ‘Dual Loss’ cost model.

§ Developed and published around 20 high quality industry reports, Conferences papers, journal articles and presentations.

Key Achievements from Previous Academic Roles:

§ Proven capacity to empowered students with industry focused study and analysis with high quality lectures and diverse engineering project

§ Successfully lead and managed multi-disciplined undergraduate projects in CQU with great teamwork, interpersonal communications and project management

§ Conducted quality research in the area of asset management, reliability engineering and mechanical engineering for industrial asset improvement

§ Attracted number of industry projects for undergraduate students from local industries

§ Established an enhanced acceptability and quality of lecture delivery to build strong confidence and industry-oriented study concepts within students

§ Be part of a teaching team in units those achieved exceptional student satisfaction feedback up to 5 out of 5

§ Excellent simulation of classroom and online sessions as a real industrial environment.

Computer Software

§ Isograph Availability Work Bench (AWB) RAMS Analysis software and Solutions

§ Asset Performance Management (APM) Meridium Software and Solutions

§ Reliasoft Reliability Engineering Software and Solutions

§ Sage ERP Software

§ SWG Facilities and Maintenance Management Software

§ CMMS – SAP, MAXIMO

§ Uniformance- Plant Information System

§ MS Project, Minitab, SPSS Statistical Data Analysis,

§ MATLAB-Simulink, Simscape

§ Strand 7 Finite Element Analysis (FEA)

§ AutoCAD

§ Autodesk Inventor

Industry Reports

Published Industry Reports

§ Chattopadhyay, G, Uddin, MG, Howie, A, 2014, ‘CRC for Rail Innovation- Curve Lubrication Final Report 2014’ Project R3.110, Brisbane, Australia.

§ Chattopadhyay, G, Uddin, MG, Sroba, P, Rasul, MG & Howie, A, 2011, ‘CRC for Rail Innovation Annual report- rail curve lubrication best practice for Australian heavy haul lines’ Project R3.110, Brisbane, Australia.

§ Chattopadhyay, G, Uddin, MG, Sroba, P, Rasul, MG & Howie, A, 2011, ‘CRC for Rail Innovation Annual Report 2011- rail curve lubrication best practice for Australian heavy haul lines’ Project R3.110, CRC for Rail Innovation, Brisbane, Australia

§ Chattopadhyay, G, Uddin, MG, 2011, ‘Rail Curve Lubrication Best Practice- Development of Wayside Lubricator Placement Model for Heavy Haul Lines’. August 2011, CRC Showcase, CQ University, Rockhampton, Australia.

PhD Research Adapted in the Australian Standards

§ Rail Industry Safety and Standards Board Australian Standards 2017, Rail gauge corner lubrication management: AS 7641:2017 (Draft), RISSB Canberra.

§ Metro Trains Melbourne (MTM) Engineering Standard Track and Civil 2017, Rail lubrication standards: MTST 000002-09:2017, MTM Melbourne.

§ Transport for NSW Standard 2015, Rail lubrication: T HR TR 0011 ST: 2015, Sydney.

Editor

Invited by SAGE Open access journal 

Consultancy Work

Currently collaborating with industry partners to generate opportunity in the field of Expertise and collaborative industry focused solutions.  

Research Supervision
Accreditation

I am currently accredited for supervision in the following:

  • 4019 Resources Engineering and Extractive Metallurgy
  • 4017 Mechanical Engineering
  • 3106 Industrial Biotechnology
  • 4099 Other Engineering
  • 4014 Manufacturing Engineering
  • 1507 Transportation and Freight Services
  • 0915 Interdisciplinary Engineering

At the level of Associate Supervisor


Current Capacity
I am currently available to supervise more research candidates
No Supervisions to display.
Research Interests
Engineering

Interdisciplinary Engineering - Interdisciplinary Engineering not elsewhere classified

Engineering

Interdisciplinary Engineering - Risk Engineering (excl. Earthquake Engineering)

Engineering

Manufacturing Engineering - Manufacturing Management
Business Improvement and Lean Six Sigma - (Process Capability, Value Stream Mapping, 5S, Non-Value Add Elimination, DMAIC Kaizen), Continuous Improvement Supply Chain Optimisation and High-Performance Materials Investigation for Enhanced Asset Life, High Performance and Cost reduction

Engineering

Manufacturing Engineering - Manufacturing Safety and Quality

Engineering

Mechanical Engineering - Tribology
Tribology (Lubrication, Friction and Wear), Rolling Contact Fatigue, Railway Engineering, Advanced Reliability Based Design

Engineering

Other Engineering - Engineering not elsewhere classified
ASSET AND MAINTENANCE MANAGEMENT Asset Whole Life Cycle Management and Cost Modelling – Lifetime Predictive Modelling, High Performance Decision Making in Asset Acquisition and Operations Innovation in Asset Management where Asset Strategy Fails Asset Strategy and Plant Maintenance Optimisation - Master Data Analysis and development of Asset management Best Practice Integrated Approach in Asset Management – Sensor Solution Modelling and Development; Information Technology, IoT & Wireless Based Non-Contact Technology Application in Geographically Widespread Asset and Statistical Data Analysis Failure Analysis - Defect Elimination, Risk Management and Optimisation RAMS Engineering – Life Data Analysis, Reliability Based Design and RAMS modelling, Advanced FMECA, Reliability Centered Maintenance (RCM) and Advanced Simulation in Reliability Engineering

Engineering

Resources Engineering and Extractive Metallurgy - Mineral Processing/Beneficiation

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