Associate Manager Maintenance
IFFCO - Delmon Products Limited
Total years of experience :19 years, 8 Months
KEY RESPONSIBILITIES:
a) Accountable for the maintenance of whole facility (Refinery, Utilities, Plastics blow molding and injection molding machines, TIN CAN manufacturing and Filling & Packaging lines, Fire hydrant system) to ensure the equipment availability at its good.
b) Planning, Executing and controlling the maintenance activities.
c) Annual Shut down Maintenance.
d) Implementing preventive and condition monitoring maintenance.
e) Process optimization for improvements
f) Devising new projects as per production and refinery requirements
g) Liaison with vendors and machines/equipment suppliers for the spares and services.
h) Daily Meetings with Refinery, Production, Quality and Warehousing for maintenance issues.
i) Finalizing maintenance services contracts.
j) Planning for the manpower requirement and staffing.
k) Looking after engineering store and maintaining parts inventory up to date.
l) Finalizing the Spare Parts Comparatives and initial approvals for PO’s.
m) Creating new vendors for engineering spare parts.
n) Monitoring EPL and analyzing to cut down EPL.
o) Implementation of TPM and 5S.
p) Implementation of eAM Oracle Module and its compliance.
q) Monitoring the WORK REQUEST system in Oracle ERP for better services and financial costs.
r) Evaluating staff performance for annual appraisals.
s) Identifying training needs of maintenance staff.
t) Implementing and strict compliance to HSE (OHSAS 18001:2007) and HACCP (ISO: 22000) standards.
Budgets / Costs / CAPEX:
- Preparing annual budget requirement (Man power, Repair and Maintenance, Power & utilities, Utility consumables) as per business plan.
- Preparing and monitoring R & M and P& U cost to remain within allocated budgets.
- Preparing CAPEX / OPEX requirements and justifications.
PROJECTS:
Installation and commissioning of following:
a) 10 & 18 Liter TIN Manufacturing Plant 1500 TIN/H.
b) 10 & 18 Liter Tin Filling Line including Serac Filler (1200 TIN / H) automatic case erector, case packer, case closure (Mondo Scaglio) and robotic palletizer (KUKA).
c) PET blow molding machines which includes 9 nos ASB-PF4-1BH machines.
d) 03 Injection molding machines (Huarong) for Caps and Handle Manufacturing.
e) Cap liner machine.
f) PET Filling Line 6000 BPH including OCME Filler, Nitrogen dosing system, Zalkin Capping, ARCA Labler. Apsol Case packing and OCME Palletizer.
g) Hugobeck Shrink wrapping for Multi packages Promo and Twin.
h) Flexi filling line Serac for 750 ml, 2 liters, 3 liters and 4 liter PET bottles.
i) Verhoven Conveyors. Modification in original design and control philosophy.
j) Working for automation of refinery and day tanks which is in process.
k) Blow molding machine Chumpower 3000 bottles per hour for the 750ml / 1 liter PET bottles.
l) Oracle Implementation leader. Creation of BOM and Formulae.
ACHIEVEMENTS:
a) Implementation of Oracle ERP with WMS for Warehouse.
b) Hiring for the production staff.
c) Cost reduction by 5 %.
d) Plant Certification from SASO Saudi Arabian Standards Organization.
e) Plant Certification for ISO 22000 HACCP Food safety management system.
f) Developing of new vendor for Cartons, Labels and HDPE / PP Materials.
KEY RESPONSIBILITIES:
As Production Engineer (May-2006 to Dec-2009):
- Responsible for the smooth operation and maintenance of production lines.
- Execution of production plan to meet the production targets.
- Responsible for maintaining Line Efficiency not below 80%
- Responsible for maintaining Production KPIs, material yields (Perform, closures, labels, shrink film, sleeves)
& Syrup yields as per set targets.
- Maintenance of production line PET for smooth run throughout the year.
- Posting of production and material consumed in SAP.
- Coordination with external vendors for timely availability of machine spare parts.
- Defining minimum inventory level levels and plan to meet them
- Defining production procedures and implement.
- Responsible for GMP.
- Making Pareto analysis of breakdowns and build corrective action plan to minimize breakdowns.
- Recording EPL and OPL and keep them below set KPI.
- Preparing CAPEX and OPEX.
- Production consumable budget preparation according to production business plan.
- Management of manpower for shift operation.
As Assistant Manager Engineering (Jan-2010 to Jun-2012):
- Responsible for Operation & Maintenance of Plant electrical & instrumentation System.
- Responsible for operation and maintenance of Electrical Substation (HT, LT, Transformers) and standby
Power generation (Generators).
- Review plant production equipment environment (e.g., technology, systems, quality, cost, efficiencies, yield)
in order to recommend process improvements.
- Synthesize data and identify problems through operational analysis in order to improve operational
performance.
- Track maintenance schedules for equipment assets in order to ensure preventive maintenance is current.
- Record and analyze plant equipment performance data using design and performance specifications in order
to ensure optimum machine reliability.
- Regularly inspect plant production support systems and equipment (e.g., HVAC, compressed air,
refrigeration, production lines, process, waste water treatment) in order to support effective plant operation.
- Measure the use of equipment spare parts by tracking spare parts transactions through use of SAP tools in
order to determine proper re-order points.
- Develop process improvement initiatives.
- Execution and supervision of new projects
- Support to production staff in troubleshooting and spares arrangements.
- Defining Repair & Maintenance budget.
- Monitoring EPL & OPL in Electrical area..
- Preparing CAPEX and OPEX.
- Monitoring EUR (Energy Use ratio)
- Sizing of Flow Meters for utilities.
- Maintaining plant PLCs, HMIs and electronic equipment.
Projects:
a) Erection and commissioning of 3.5MW Substation and 02 1400KVA Gensets, 01 no. 11KV automatic voltage regulator.
b) Extension of load from 963KW to 3.5MW from Mepco.
c) Erection of Pet line Project (18000BPH Pet filling line by Sidel-Simonazzi). Pet Line Includes High speed 18000BPH Blow Molding SBO10 Universal Machine. It’s a fully automatic line and also Line includes mineral water plant.
d) Erection of Juice Line Project (30, 000BPH Glass juice filling line, a joint venture of TetraPak, Krones and Paktool).
Coca Cola RYK plant has 01 Pet Line, 03 RGB lines and 01 Juice Line. Plant Industrial services includes Ammonia system, 40bar HP Air compressor, LP air compressors, 08Ton boiler.
I have participated in the Installation and commissioning of Textile Project-2, and led the team for Conewinding Department.
KEY RESPONSIBILITIES:
Responsible for trouble free operation & maintenance of plant equipment both Electrical & Electronics.
Responsible for trouble free operation & maintenance of HT, LT, Transformers & Generators.
Troubleshooting of Microset Mars PLCs.
Troubleshooting and programming of Reel Inverters.
Responsible for trouble free operation of DCS system.
Prepare maintenance plans for Electrical & Electronics Equipment according to ISO 9001:2000 quality system and its implementation & execution.
Perform calibration of Instruments.
Prepare BOQs for new installations.
Managing spare parts regarding Electrical & Electronics using Oracle ERP system.
Management of Electrical & Electronics Department.
1st Division. 72.38 marks
1st Division Marks 75.27%