Assistant Manager-Maintenance, Projects, Control Sys and Utilities
Coca Cola Beverages
Total years of experience :17 years, 8 Months
• I was the Lead for implementing TPM (Total Productive Maintenance) at our plant. I have tuned our production lines for optimum performance and improved the plant's productive efficiency form 81.9% to 85.2%.
• Increased machine uptime from 95% to 98.5% through the RCA (Root Causes Analyses), machine reliability studies, and implantation of corrective actions.
• I have regularly tracked and thus Improved the EUR (Energy Usage Ratio) from 0.38 to 0.28 and the WUR (Water Usage Ratio) from 1.55 to 1.40
• Under my management, my team Implemented 5S & the JH (Jishu Hozen / Autonomous Maintenance) and reduced the number of breakdowns.
• I have played a key role in improving the plant’s MTTR (Mean Time to Repair) from 17.5 to 16.6, which was of 5% improvement & MTBF (Mean Time between Failures) from 1.42 to 2.05, which was of 44% improvement.
• Improved spare parts availability from 78% to 90%.
• I have outperformed on the functions of troubleshooting & breakdown/preventive/predictive maintenance for bringing the plant equipment downtime to a minimum level.
• I have made a calibration set up for the field instruments making the maintenance team capable of handling the instruments and that also led to cutting down the cost for third party calibration.
• I have got the damaged electrical and instrumentation equipment repaired and tested. Kept it in a separate store for use first and then if not available then the store material to be used. Reducing cost.
• I have rendered services as a team leader duties & supervised the preparation of new drawings, coordinating with various engineering disciplines during commissioning & development, and reviewed & formulated electrical, instrumentation & control design documents, P&IDs, conceptual & detailed electrical and instrument designs & layouts.
• I have selected new vendors and procured materials for a better price than the OEM. Also, I have selected new contractors and have got the work done always at a better cost.
• As an Instrumentation Lead, I had always maintained all the technical documentation of the plant equipment that is necessary for the troubleshooting of the instruments. Also, I was responsible for taking/proposing new improvements in control systems in the plant.
• I have always maintained and managed the critical spares for the entire plant.
• I have formulated several checklists for the tracking of the instruments on a regular basis by which the total equipment uptime and the production line efficiencies also improved.
• I have always given importance to the adherence to maintenance and calibration schedules for all the process instruments.
• I have implemented the Six Sigma methodologies to back-up Production & Quality Control and stabilized the process.
• As the team-lead for the engineering department, I have proposed, planned, implemented, reviewed, coordinated, inspected, and tested the CAPEX projects at our plant.
• I had also devised regular lubrication, greasing, and oil change checklists for all the plant level equipment.
• I have developed hazard control processes, methods, and programs, also advised ways of controlling potential threats to hazards identified.
• I have developed HSE awareness, took training sessions in a range of HSE topics such as risk assessment, manual handling, and hazard identification.
• I have participated in incident investigations to determine the root cause, identify key lessons, and make recommendations to prevent a recurrence.
• I have conducted audits on the effectiveness of hazard control programs.
• I always prepare future safety plans based on past experiences and facts.
• Maintained Process Equipment, pumps, Filling & Packaging equipments, Utility equipment, Material handling & other infrastructure facilities, Safety & firefighting equipment, Pollution / Effluent treatment equipment /facilities etc), Lighting, Earthing protection measures, Lightning protection measures etc.
• Planned, supervised & monitored the site electrical installation works as per the approved drawings, standards. Also, supervised and installed HT equipment, LT Panels, switch gears, cabling, cable trays including energizing of electrical equipment, Field instruments, control valves, gauges, cabling, junction boxes.
• I have also planned, supervised & monitored the installation of field instrumentation, communication network & process Control system as per drawings.
• Installed many PLC panels & control room hardware & SCADA / process control software with flow, pressure, temperature, level, weight measuring & control instruments.
• Our team and I had undertaken the installation, testing, carry out FAT/SAT and commissioning of the electrical and instrumentation systems.
• I have coordinated with our contractor engineers for estimation, preparing and assigning the resources such as manpower, materials, consumables, equipment, tools, etc., required for all electrical and instrumentation related maintenance/project works prior to execution.
• I have provided health and safety measures in a working environment and have supported staff with the identification of environmental aspects and determining the project objectives and targets also I have Identified and evaluated the unsafe environment and practices.
• I have monitored the implementation of safety plans and objectives, track safety systems by using check list and spreadsheets.
• Maintained and managed equipment and processes related to health and safety.
• I have managed designing, installing & commissioning, calibration and maintenance of Transmitters, RTD's, Thermocouples, Sensors, and all type of level & pressure sensors. Also I have Administered all the ongoing maintenance & customer support for the projects completed.
• I have conducted installation, calibration & troubleshooting of analyzers & all the instrumentation systems along with several electrical turnkey projects with the electrical panels, AC/DC drives and electrical distribution systems.
• As a team leader, i have executed plans and coordinated activities for the maintenance & for the safe operation, also for the functionality of all the types of automation & instrumentation & control systems equipment.
• Trouble shooting of the Electrical and Instrumentation systems.
• Ensured project document compilation. Perform system line check, field check and verification.
• Responsible for implementations and monitoring of all electrical & instrumentation related works at site.
• Ensured proper reviewing of engineering work packages / drawings for completeness.
• I would interpret the construction drawings and study the contract documents and applicable standards or specifications prior to execution of any job.
• I planned the execution of all electrical & instrumentation related works in coordination with other mechanical and civil groups.
• I would ensure progress, quality control, quantity surveying takes places and is recorded as per the contract document requirements and always look for recommended ways save cost.
• I coordinated with consultant’s/ contractor representatives for any site instruction and inspection of work.
• I assigned targets for accomplishments and ensure targets are met on daily basis for all electrical & instrumentation groups at site.
• I would submit daily site reports, inspection requests, estimates and all applicable monitoring reports and on regular basis.
• I support the Project Manager in accomplishing all the goals and targets for the electrical team at the site.
• I ensured that all the works done are in accordance with the drawings, contract documents, project specifications, and all applicable standards whether local, national or international standards.
• I have co-ordinates with other disciplines for space planning, electrical load estimate, interfacing
Key Result Areas:
Ensured project document compilation. Perform system line check, field check and verification.
Responsible for implementations and monitoring of all electrical & instrumentation related works at site.
Ensured proper reviewing of engineering work packages / drawings for completeness.
I interpret construction drawings and study the contract documents and applicable standards or specifications prior
to execution of any job.
I plan the execution of all electrical & instrumentation related works in coordination with other mechanical and civil
groups.
I Ensure progress, quality control, quantity surveying takes places and is recorded as per the contract document
requirements and always look for recommended ways save cost.
Plan and analyze all possible construction methodologies and recommends the best options to the Project Manager
for approval prior to execution at site.
Coordinate with Consultant’s/ Contractor representatives for any site instruction and inspection of work.
Assign targets for accomplishments and ensure targets are met on daily basis for all electrical & instrumentation
groups at site.
I submit site daily reports, inspection requests, estimates and all applicable monitoring reports on regular basis.
I support the Project Manager in accomplishing all the goals and targets for the electrical team at the site.
Ensure that all the works done are in accordance with the approved construction drawings, contract documents,
project specifications, and all applicable standards whether local, national or international standards.
Review of Material Checking & Submittals, shop drawings, site coordination etc.
Co-ordination with other disciplines for space planning, electrical load estimate, interfacing
Electronics & Communications Engineering