Marcelo Rocha
General Manager at Pertama Ferroalloy Sdn. Bhd.- Claim this Profile
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Bio
Experience
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General Manager
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Mar 2019 - Present
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Head of Ferroalloy Production
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Nov 2016 - Nov 2018
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FeCr / FeSi Operations Manager
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Jul 2010 - Aug 2016
Leader in the research project in partnership with SINTEF, focused on mineralogical investigations of chromite ore from Ferbasa and Cr losses to slag in HCFeCr production. It was possible to optimize the use of chrome ores. Increase in the domestic market share of HCFeCr due to the use of industrial wastes from the main customer of FERBASA and production of HCFeCr with low phosphorus. FeCr’s tapping area layout rehabilitation, reducing the lost workday accidents frequency to zero in 2016 and… Leader in the research project in partnership with SINTEF, focused on mineralogical investigations of chromite ore from Ferbasa and Cr losses to slag in HCFeCr production. It was possible to optimize the use of chrome ores. Increase in the domestic market share of HCFeCr due to the use of industrial wastes from the main customer of FERBASA and production of HCFeCr with low phosphorus. FeCr’s tapping area layout rehabilitation, reducing the lost workday accidents frequency to zero in 2016 and resulting in improvements in environmental conditions. Increase in productivity in FeSi75 from 20 to 37 t / HH through process optimization and automation. Development of alternative reducers in the production of FeSi75. Show more Show less
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Safety, Health, Environment and Quality Superintendent
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Jan 2009 - Jul 2010
• Responsible for managing the integrated system (safety, health, environment and quality) of the whole group Magnesita Refratários S.A., which is composed of multi sites: 09 plants (08 in Brazil and 01 in Argentina), 01 corporate center and 09 contracts for services in steel companies in Latin America. Challenges for 2009: excellence in management systems, continual improvement of ISO 9001 (12 sites), ISO 14001 (04 sites) and OHSAS 18001 (01 sites), implementation and certification of ISO… • Responsible for managing the integrated system (safety, health, environment and quality) of the whole group Magnesita Refratários S.A., which is composed of multi sites: 09 plants (08 in Brazil and 01 in Argentina), 01 corporate center and 09 contracts for services in steel companies in Latin America. Challenges for 2009: excellence in management systems, continual improvement of ISO 9001 (12 sites), ISO 14001 (04 sites) and OHSAS 18001 (01 sites), implementation and certification of ISO 9001 in Usiminas and CSN, implementation and certification of ISO 14001 in Arcelormittal Tubarão and Usiminas, implementation and certification of OHSAS Arcelormittal Tubarão. Show more Show less
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Brazil Operations General Manager
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Jun 2005 - Nov 2008
• Led plant’s organizational restructure, largest Mn ferro alloy plant of Latin America, with a capacity of 200 kt/ year of alloys, 165 kt/year of sinter and 156 MVA’s installed. In 2008, implemented a new organizational structure based on process, reduced by 51% the lost workday accident frequency, the plant received a favorable ruling from the CRA (local environmental protection agency) for closing of the TAC (terms of environmental agreements) and elaborated the project for relining and… • Led plant’s organizational restructure, largest Mn ferro alloy plant of Latin America, with a capacity of 200 kt/ year of alloys, 165 kt/year of sinter and 156 MVA’s installed. In 2008, implemented a new organizational structure based on process, reduced by 51% the lost workday accident frequency, the plant received a favorable ruling from the CRA (local environmental protection agency) for closing of the TAC (terms of environmental agreements) and elaborated the project for relining and modernization of the electric reduction furnaces and implementation of the new converter for production of FeMnMC. • Led Manganese and Alloys Brazil Operations organizational restructure, leveraging EBTIDA from US$94,4 MM (2005) to US$195 MM (2007) and later US$800 MM for 2008 by renegotiating contracts and the “responsible reduction” in the number of managers by 40% and of its own and outsourced workforce from 5400 to 2800 employees. Reduction of the asset base (BCA) by US$104 MM through divestment of non-core assets and inventory reduction, raising the CFROG from 8,7% (2006) to 19,7% (2007). Simplification of the ferro alloys plants located in Brazil and an investment focus on operational improvements, change of the strategy for reductors use, replacing charcoal by coke, thus modifying the structure of costs. Show more Show less
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Industrial Director
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Mar 2002 - May 2005
Rio Doce Manganese Europe (RDME) – (03/2002 to 05/2005)Industrial Director Major accomplishments:• Plant located in France with capacity of 140 kt/year of alloys, 400 kt/year of sinter manganese and 100 employees. Reduced costs by implementing new technologies and improved the operational performance through labor safety programs and implementation of the ISO-9001/2000, ISO 14001 and OHS 18001. Led the first relining of the biggest electric furnace of the world (102 MVA)… Rio Doce Manganese Europe (RDME) – (03/2002 to 05/2005)Industrial Director Major accomplishments:• Plant located in France with capacity of 140 kt/year of alloys, 400 kt/year of sinter manganese and 100 employees. Reduced costs by implementing new technologies and improved the operational performance through labor safety programs and implementation of the ISO-9001/2000, ISO 14001 and OHS 18001. Led the first relining of the biggest electric furnace of the world (102 MVA). Technical support in the start up of the ferro alloy plant acquired in 2003 in Moi Rana (Norway). Show more Show less
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Production Manager
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Jan 2001 - Feb 2002
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Production Manager
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Oct 1996 - Dec 2000
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Metallurgy Manager
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Apr 1991 - Jun 1996
INDÚSTRIA E COMÉRCIO DE MINÉRIOS S.A. – CAEMI - CFA 1991 to 1996 Metallurgy ManagerMajor accomplishments: • Ferro alloy plant located in Santana (Amapá State) with capacity of 24 kt/year of alloys and 180kt/year of sinter manganese. I played a decisive role in the optimization of integrated system mine/alloy, operational KPI’s were considered benchmarks in the operations of Mn. Developed the process of Chromium ore pellets and its conversion Cr ferro alloy. Led the shut… INDÚSTRIA E COMÉRCIO DE MINÉRIOS S.A. – CAEMI - CFA 1991 to 1996 Metallurgy ManagerMajor accomplishments: • Ferro alloy plant located in Santana (Amapá State) with capacity of 24 kt/year of alloys and 180kt/year of sinter manganese. I played a decisive role in the optimization of integrated system mine/alloy, operational KPI’s were considered benchmarks in the operations of Mn. Developed the process of Chromium ore pellets and its conversion Cr ferro alloy. Led the shut down of the plant in 1996. Show more Show less
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Education
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FACULDADE DE TECNOLOGIA SENAI CIMATEC
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Faculdade Pitágoras
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FGV - Fundação Getulio Vargas
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IMD
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Trend School
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MIT Sloan School of Management
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HEC Paris
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Universidade Federal de Juiz de Fora
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UFOP - Universidade Federal de Ouro Preto