Plant Maintenance Engineer With Exp. In Utilities & Facilities
Falcon Technologies International L.L.C
Total years of experience :13 years, 8 Months
Key Result Areas - Plant Maintenance
• Designing and implementing cost-effective equipment modifications to help improve safety and reliability, making sure a product can be made reliable and will perform consistently in specified operating environments
• Developing, testing and evaluating theoretical designs, recommending modifications following prototype test results;
• Managing projects using MS Project 2013
• Designing mechanical parts in ACAD and cooperating with local vendors for fabrication, considering the implications of issues such as cost, safety and time constraints
• Supporting team members by sharing the theoretical knowledge and provide training
• Directing, instructing and supervising Maintenance Technicians, Carrying out quality inspections on jobs
• Participating in the BTR, Six Sigma project and work as per TPM and 5S concept
• Responsible for daily work management, Why-Why analysis and CAPA, and implementation of final action on root causes
• OLE improvement by reducing breakdowns and minor stoppages
• Improve MTBF & MTTR by doing continuous improvement in the equipment (Kaizen)
• Implementation & development of pokayoke for no fault forward
• Implementation of JH/PM (TPM) on assembly line equipment’s
• Implementation of CBM (condition-based monitoring) for parameter current, pneumatic cylinder, sensors etc.
• Evaluation of new equipment, Supplier development (local service support) for spares and equipment Services, Selection of equipment suitable for the process, Cost Negotiation with supplier and development of local support for quick service
• Selection of equipment configuration to standardize with existing equipment configuration
• Budget preparation and utilization effectively
• Testing and inspection of new equipment (SAT and FAT)
• Arrange installation and commissioning of new equipment
• Preparation of scope of requirement, PR generation
• Spare part management equipment-wise
Key Result Areas - Utilities & Facilities
• Operations & maintenance of Chillers, Air compressors, Cooling towers, Nitrogen generator, RO plant, Vacuum pumps, Heat exchangers, HVAC, Firefighting, Plumbing, BMS, Blowers, Pumps, Motors etc.
• Keeping all building & utilities equipment’s / machines in sound healthy operational condition by providing support to the team with proper guidance & planning
• Responsible for daily work management and all types of preventive & facilities maintenance
• Utilizing existing resources & suitable means to reduce the production costs while meeting all the quality standards
• Daily maintenance planning, work distribution, breakdown analysis and report submission to HOD
• Handling projects to provide required facilities for the installation of new manufacturing machines and building improvement & modification
• Consistently working on cost reduction of water as well as electricity, even controlling inventory for the general maintenance
• Annual budget preparation and shutdown planning
• Material procurement through SAP and ERP software and maintaining inventory of most critical spares
• Good knowledge of BMS & HVAC operation and maintenance
• Knowledge of cGMP, ISO, 5s related documentation
• Diagnosing breakdown problems, designing maintenance SOP documents
• Preparing monthly, quarterly, half yearly and annual maintenance KPI reports
• Implementing & monitoring, TPM & 5S working concept to improve the machines & work force efficiency
• Supporting departmental vision for continuous improvement in all aspects of the organization
Highlights
• Line modification from CD - DVD - 2019
• Retrofit LED light - 2018
• Nitrogen generator installation - 2018
• Cooling tower condenser pipe replacement - 2017
• Piovan PC (Polycarbonate) supply network modification for use of high grade PC - 2016
Oct’11 - July’14
Key Result Areas
•Looking after the plant operations, maintenance & projects while adhering to spare parts, inventory, budget and environmental & safety regulations
•Ensuring implementation of a wide variety of engineering solutions to increase equipment availability & net operating rate, reduce operation losses and achieve standard & acceptable production rates
•Accountable for maintaining molds inventory, bladder rings inventory & mold repair works
•Responsible for calibration of load cell in Tyre Uniformity Machine; conducting repeatability check with Master Tyres
•Planning and Execution of Scheduled Lubrication & Shutdown jobs of all the Equipment’s
•Execution of Preventive Maintenance jobs as per SAP generated orders
•Workman Safety & Machine Safety, while carrying out different maintenance and fabrication jobs
•Analyzing the breakdown time hours (MTBF & MTTR) & its corrective action plan
•Worked with company’s vendors and supervised subcontractors during various maintenance projects to ensure proper completion of work performed at customers’ facilities.
•Involved in installation & commissioning of Press as per layout; accountable for study and assembly of hydraulic & pneumatic pipelines as per the drawings
Highlights
•Distinction of having introduced and developed an approach for maintenance of incorporating principles of TPM & Kaizen philosophy and then created plans, programs and strategies for personnel & equipment improvement
•Instrumental in introducing the Kaizen activities in 2012
•Leadership development, man power handling & developing the technical skills of the technician
•Successfully carried out installation & commissioning of 48’’ & 36’’ Hydraulic Tyre Curing Presses - HF & Herbert, Auto PCI, Tyre Uniformity and Optimization Machine - 2013
Key Result Areas
• Preventive & Predictive Maintenance of Utility equipment’s including Stationary & Rotating Equipment’s, Boilers, Chillers, Air Compressors, Cooling Towers, Centrifugal Pumps, Blowers, AHU’S, Firefighting System, Heat Exchangers etc.
• Planning and Execution of Shutdown maintenance; Execution of daily activities of lubrication
• Managing & coordinating the schedule visits of service contractor of Compressors, Chillers & Water treatment
• Generating & Updating reports of Diesel oil, Furnace oil, Raw water consumption & preparation of monthly reports
• Maintaining complete machine history records
• Maintaining daily preventive check lists
• Raising Indents, Capital Expenditure Requisitions, Work Orders, Work Requisitions
• Inventory management of the critical spares of the equipment
• Equipment Qualification & Requalification