Mukuram Solomon Raj

Led a cross-functional team for Mechanical, Electrical and Instrumentation maintenance, reliability and projects across the plant
• Managed maintenance and reliability activities for Reversal type Regenerative Furnaces, Hot End (Annealing / Tin Bath / Lehr), Cold End (Capping line to Packaging), Warehouse and Coater lines for industrial and domestic glass products
• Utilized CMMS and asset management practices to plan, execute and track maintenance activities and ensure compliance with internal and external standards
• Applied analytical skills, data analysis and problem-solving methodologies to support predictive maintenance and improve equipment performance and uptime
• Performed root cause analysis (RCA) on recurring failures and implemented corrective actions in collaboration with cross-functional teams
• Supported and implemented reliability strategies focused on system uptime improvement, cost control and waste reduction
• Handled CAPEX and OPEX projects aimed at supporting production uptime, equipment availability and reliabilityfocused investments
• Ensured alignment of maintenance and reliability activities with plant production requirements, safety standards and compliance obligations
• Define and track reliability KPIs, including MTBF, MTTR, availability, and failure rates
• Lead root cause analysis investigations using 5-Why and fishbone methodologies on critical failures
• Create and update reliability standards, procedures, and best practices across engineering and operations

• Led end-to-end project management for state-of-the-art smart
plant instrumentation across 6 greenfield plants, covering
feed, design, detail engineering, functional & technical, safety
analysis, procurement, erection, commissioning and
stabilization/maintenance for water-based, solvent-based
paints, distemper, colorants, wood finish and utilities within an
overall budget of 1670 Cr INR and plant capacity of 2.3 MLPA
each.
• Drove smart plant design and process/factory automation for
6 plants, including P&ID with interlocks, PFD, single line
diagrams, detailed instrumentation drawings, HAZOP studies,
3D modelling (PDMS) and hook-up drawings.
• Participate in HAZOP, SIL, and risk assessments for new
instrumentation systems
• Finalized instrumentation engineering deliverables such as
technical and functional instrument index for 1.2 lakh I/O,
instrumentation MRs (BOQ)/RFQs, layout drawings for
panels/control/server rooms, cable/tray/JB schedules and
system/network architecture.
• Defined control philosophies and IT-OT system architecture
for ABB DCS, PLCs, virtual servers and communication
networks, integrating Control & Plant Networks and multiple
protocols including Profibus, Profinet, TCP/IP, Canbus,
Modbus TCP/IP, OPC UA, OPC DA, OPC HDA and OPC AE
as well as Extended Warehouse Management System.
• Managed procurement and technical/vendor evaluation for
major instrumentation scope, including field instruments (1500
nos), load cells (2000 nos), automated valves (20000 nos),
power and signal cables (24 kms) and ABB DCS with 1.2 lakh
IOs, and finalized tenders for instrumentation contractors with
600 manpower size.
• Finalized instrumentation scope and concept notes for utilities
including boiler (3 ton/hr), nitrogen and compressed air plant
(3300 CFM), cooling towers (88 KLD), chillers, water
treatment plant (650 KLD), effluent (150 KLD) and sewage
(30 KLD) treatment plants, and pigging & Powder coveying
system.
• Led erection, commissioning and stabilization of the Panipat
plant with 47000 IOs within 2 years, and handled
instrumentation maintenance for the water paint block (2
MLPA) and solvent paint block (0.3 MLPA).
• Coordinated Design/Detail Engineering, Concept Notes,
Technical deliverables, BOQ Extraction, Procurement,
Erection/Commissioning & Maintenance of Eletrical (6.2 MW)
Load list, Transformers, HT/LT Switch gears, Panels,
MCC/PCC Layouts, Cables, Motors, Lifts, Renewable Energy
(Solar Plant 2 MW), Required approvals & Compliances.
• Supervised a 22-member instrumentation team (5 on-roll and
17 contractor staff), overseeing safety compliance, learning
and development, change management, KAIZEN,
improvement projects, CAPEX/OPEX control, material and
spares management, vendor and contractor management,
and legal/statutory compliance.
• Implemented and monitored JSA, HAZOP, root cause
analysis (Why-Why, Fishbone), CAPA, SOP/SMP, skill matrix,
HIRA and FMEA documentation to enhance reliability,
availability and safety of instrumentation systems.
• Train and mentor technicians and junior engineers on
instrumentation best practices and diagnostics

• Led installation and commissioning of state-of-the-art
instrumentation and control systems for a 200 Cr INR
greenfield paints project (3 MLPA capacity) with Jacobs
Consultant, including ABB DCS with 44, 000 I/O, 600 loadcell
systems on Profibus, 2, 200 field instruments, 1, 700 DOL/VFD
motors on Profinet and Modbus TCP/IP, 7, 756 valves, 800 km
of cables, 1, 800 FA/PA devices, 200 CCTV cameras and 6
weighbridges (60 ton each), coordinating a workforce of 250
personnel.
• Led design, procurement, installation and commissioning of a
5.5 Cr INR brownfield instrumentation project for a 3, 000 KL
monomer tank farm, comprising 750 I/O, 10 loadcell systems,
190 valves, 60 field instruments and a 30-person contract
workforce, executed in 2019-2020.
• Managed instrumentation for associated utilities including
boiler, nitrogen and compressed air plant, cooling towers,
chillers, water treatment plant, effluent treatment plant,
sewage treatment plant and pigging lines, ensuring reliable
operation and integration with process control systems.
• Supervised a team of 5 members for plant stabilization and
maintenance over 2 years, ensuring continuity of operations
and adherence to safety and quality standards.
• Drove initiatives to improve plant production performance
using TRACC and Six Sigma methodologies, focusing on
process optimization and reduction of operational losses.
• Implemented and validated logic changes in DCS, PLC and
HMI systems (ABB, Honeywell, Yokogawa, Hollysys) through
formal change management procedures and approval
workflows.
• Managed end-to-end instrumentation for emulsion block,
powder (silo), utilities, water treatment plants, boilers, chillers,
cooling towers, hydro pneumatic systems, robotics,
conveyors, EWM and packing machines, ensuring proper
integration and control.
• Conducted training of contract workforce on standard
maintenance procedures (SMPs), calibrations, safe work
practices, JSA, HAZOP, root cause analysis (why-why,
fishbone) and quality documentation standards.
• Handled safety oversight, OPEX budgeting and estimation,
vendor development, spares management, cost control,
SOP/SMP trainings and SAP-based preventive maintenance
within the instrumentation scope.
• Performed maintenance and troubleshooting of field
instruments, loadcells, pigging lines, SWAS panels (ppm, %
analyzers), control valves and communication networks
including Profibus, Profinet, OFC and LAN.
• Prepared and presented weekly MIS data to top
management, discussing plant KPI and safety KPI, and
recommended actions for performance and safety
improvements.
• Conducted weekly reviews of contractor teams on safety
compliance and maintenance performance KPIs, driving
accountability and continuous improvement.
• Lead calibration, testing, and maintenance of field
instruments to ensure accuracy and regulatory compliance
• Develop, review, and optimize instrumentation preventive
maintenance plans to minimize downtime and failures
• Troubleshoot complex instrumentation and control system
issues, providing root cause analysis and corrective actions
• Analyze process data and control performance to recommend
improvements in reliability, accuracy, and efficiency
• Plan and control instrumentation department budgets, spares
inventory, and lifecycle replacement strategies

• Operated and supported Lead Smelters (Blast and EAF
furnaces), copper recovery from CuS dross (reverberatory
furnaces), sulphuric acid (H2SO4) plants, and cryogenic
plants for oxygen and nitrogen gas production, including
associated utilities and storage
• Handled and monitored FFH, FO, FUD, diesel and petroleum
storage and supply skids, effluent water treatment plants
(EWT), compressed air plants, boilers, pneumatic conveying
systems, cell house and utility areas
• Performed maintenance, calibration and troubleshooting of
field instruments (temperature, pressure, flow, level, burners,
vibration monitoring, PA systems, fire and smoke detectors,
valves) from ABB, Emerson, E&H, Siemens and other major
OEMs
• Maintained and calibrated analytical instruments for CO, CO2,
SO2, O2, pH, ORP, TDS, phosphate, silica, conductivity, DO,
concentration, opacity, THC analyzers and detectors from
Emerson, E&H, Siemens, ABB and similar makes
• Supported operation, diagnostics and communication of
Profibus, OFC, LAN networks and industrial automation
systems including DCS, PLC, HMI, SCADA and MIS,
ensuring reliable data flow and control
• Performed maintenance, back-up and restoration of DCS,
PLC, SCADA and MIS readings and control configurations,
assisting the control room in monitoring and achieving KPIs
• Responded to instrumentation and control breakdowns,
identified root causes and implemented corrective actions to
restore process operations in the minimum possible duration
• Planned and executed shutdown and breakdown
maintenance activities for instrumentation on a priority basis,
coordinating with operations and other departments
• Attended and closed SAP PM and MM notifications for daily
preventive maintenance and corrective actions on instruments
and equipment, ensuring compliance with maintenance
schedules
• Implemented online and offline plant modifications, KAIZEN
activities and improvements in equipment and systems
through DCS/PLC logic changes where required
• Updated and refined SMPs and SOPs for instrumentation
activities, incorporating safety measures via JSA and JCC to
minimize hazards
• Conducted field inspections to identify near-miss incidents
and safety violations related to process and maintenance
operations, and updated findings in HRMS to support EOHS
sustainability
• Promoted and maintained 5S practices in workshops and
DCS cabinet rooms to improve safety, organization and
reliability of instrumentation systems
• Updated MIS reports to provide instrumentation and
maintenance-related information to top management
• Processed material code releases and purchase orders for
instrumentation and related equipment through E-Nomcat and
SAP, coordinating with procurement and stores
• Created SIVs in SAP for the issue and retrieval of
instruments, spares and equipment from central stores and
managed spare availability
• Drove 5S, KAIZEN, FIP, FMEA and RCA initiatives within the
instrumentation team, and contributed to SMP/SOP revisions
and on-the-job training for team members
• Monitored and supported CAPEX, OPEX and shutdown
budget estimations related to instrumentation, supervised jobs
and contributed to effective spare management
• Calibrate, test, and validate field instruments to ensure
accuracy and regulatory compliance
• Develop, review, and update P&ID diagrams and
instrumentation loop drawings
• Prepare technical documentation, calibration reports, and
maintenance records for audits and inspections