Maintenance Manager
Resume:
Sabu Kurian
*** **** ****** **** ***** Prairie, TX 75052
**********@**********.***
Professional Profile
Manufacturing leader with strong problem solving and leadership skills. Strong and proven working
background in Mechanical Engineering, Maintenance and Continuous Improvement. History of
reducing cost while increasing efficiency and effectiveness. Build trusting customer relationships with
key clients including Pepsi Co, Scripto Tokai, John Deere, Alko-Kober and EZ-Go. Develop highly
effective production teams.
Skills
Manufacturing & Operations Mechanical Engineering
Bottling Process New Employee Training
Familiar with high speed OSHA 511 - Safety
production/packaging systems Budget Management
Leadership & Employee Development Space Planning
Tool Design & Production MS Word / Excel / PowerPoint
Customer Relationships PeopleSoft / E-Time
Inventory Control AutoCAD
Certified Internal Auditor CMM Measurement Tools
Quality Assurance Lean & Six Sigma
ISO9000 / QS9000 / TS16949 5S
Trouble shoot and repair of Scientific methodologies such as Cause
manufacturing equipment & Effect, FMEA, SPC
Machine tools including mills, Lath, Welding
drill and surface grinder.
Education & Certifications
• Mechanical Engineering BSME - Kerala University, India
• Lean & Six Sigma Green Belt - 2009 UT Dallas, TX
• AutoCAD Mountain View Community College, TX
• Teamwork Discovery Lean Manufacturing Dana Corporate Training
• OSHA Health & Safety Certified Texas A&M Extension Service
• First Aid and CPR Certified Cintas First Aid & Safety
• Impact Certified (Kaizen) Dana Corporate Training
• Certified Internal Auditor - TS16949/ISO9000
Key Accomplishments
Proven ability to turn around departmental performance. As a Maintenance Manager for
Affinia - Dallas:
Assumed responsibility for the Maintenance department, which consistently exceeded budget
spend.
Within 3 months, reduced cost and spending to ensure the department was within or below budget
on an ongoing basis.
Reduced overtime and utilized MP2 (Preventive & Predictive Maintenance program) tool to ensure
that manpower was allocated effectively and equipment reliability was maintained.
Cut extraneous costs by closely monitoring ordering and tightening inventory controls.
Re-layout of the manufacturing area to improve process flow, reduce material handling efforts and
increase customer order visibility and tracking on shop floor.
Assisted the Mexican engineering team in planning new site layout, utility requirements and
maintenance schedules and inventories to relocate the plant production equipment into the new
Juarez, Mexico facility.
Implement processes to increase safety and decrease accident rates . As a
Maintenance Manager for Affinia - Dallas:
Completed OSHA 511 standard for general Industry course to learn effective safety strategies.
Trained employees in the DuPont STOP (Safety Training and Observation Program) training to
reduce the accident rate by 50% in 1 year.
Taught employees how to observe potentially dangerous situations and provided tools to
proactively correct the issues.
Strong problem-solver. Provide excellent customer service. As an Original
Equipment (OE) Production Supervisor for Affinia - Dallas:
Took over the OE department with 44 employees, which was experiencing high customer complaint
levels and high backorder rates.
Visited client locations to evaluate quality issues.
Re-organized the production schedule. Changed floor design & processes to improve efficiency.
Trained and motivated the team. Communicated customer needs and reviewed expectations through
improved documented work instructions. Established daily production goals and monthly
communications meetings with employees to celebrate their achievements.
Within 4 months, achieved 100% on-time delivery.
Dependable Leader. Effective with highly diverse teams. Lead up to 44 employees.
Teams have included team members from 4 different countries speaking 3 different languages. Work
through cultural differences to ensure that all employees are well trained and have the proper
incentives and information to perform well.
Strong balance of mechanical, business and leadership skills . Utilize AutoCAD
programs to help designed new tools for plant operations. Assisted in restructuring the plant layout
to provide a highly efficient work flow. As a TS16949 Internal Auditor, have written and maintained
work instructions for Original Equipment Production process and Maintenance Process.
Career Experience
Affinia Group, Inc / Brake Parts Inc. 1989 - 2009
Affinia Group is a brake, chassis and filtration parts industry leader with locations in 19 countries worldwide. They
are known for manufacturing excellence including Raybestos brand brakes, first developed in 1906. Brake Parts Inc.,
a subsidiary of Affinia, manufactures aftermarket and OE brake parts for major clients such as NAPA Auto Parts,
CARQUEST, ACDelco and TRW/Chrysler.
Maintenance Manager Dallas, TX
Led building and equipment maintenance operations for a high volume, 100,000 square foot brake shoe
manufacturing plant.
Quickly contained cost to move department from a position of consistently over spending the budget to
consistently meeting or exceeding budget expectations.
Managed 7 Maintenance technicians in 2 shifts responsible for all manufacturing equipment, building
maintenance and materials handling equipment.
Ensured plant productivity by quickly resolving all mechanical issues.
Oversaw waste management and recycling activities. Managed vendor relationships.
Assisted with changes to the plant layout. Rearrange equipment.
Assisted with relocating the plant to the Juarez, Mexico location including shipping the machineries and
reinstalling them to new facility, train new operators and test run production equipment.
OE Production Supervisor Fredericksburg, VA Dallas, TX
Led the manufacturing of brake shoes for new vehicles. Clients included TRW, Alko-Kober, Dana Spicer and
GMSPO.
Directed up to 44 employees producing up to 15,000 pieces per day.
Focused on quality and on-time delivery.
Built relationships with clients. Significantly increased customer satisfaction and reduced backorders.
Transitioned OE production from the Fredericksburg, VA to the Dallas, TX. Worked to maintain customer
line fill at 90%+ during the transition.
Wrote work instructions for all positions in the OE Production department and trained all employees on
work instructions. Helped to implement TS16949 standards.
Served as an internal TS16949 Auditor.
OE Night Shift Supervisor Fredericksburg, VA
Oversaw night shift operations. Managed 20 employees in a production environment.
Maintenance Mechanic Irvine, CA Fredericksburg, VA
Repaired and maintained large manufacturing equipment for riveted and bonded brake shoes and disc pads.
Scripto Tokai of America Rancho Cucamonga, CA 1987 -1989
Manufacturing of cigarette lighters and ball point pens.
Maintenance Mechanic
Repaired and maintained large manufacturing equipment including Injection Molds, Power Conveyors, Automatic
High-Speed Assembling Machines and High-Speed Packaging Systems.
Pepsi - Cola. Abu Dhabi, United Arab Emirates 1982 - 1986
Maintenance Manager
Led equipment and facility maintenance at a high profile soft-drink bottling operation/ammonia ice plant
responsible for distribution in the Middle East.
Designed new plant layout concentrating on production flow and efficiency.
Managed project to implement a new bottling system in the plant.
Successfully implemented project to begin the new bottling process, which included retrofitting the
equipment to accommodate changes from a returnable bottle system to non-returnable bottle system.
Oversaw a crew of 15 maintenance staff.
Oversaw product delivery fleet maintenance operations.
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