Maintenance Engineering

Sushil Kumar

**/**, ******* **********, **********, Klongnueng,Pathumthani-12120. Thailand.

+66-81-937-**** +66-94-649-**** **********@*****.***

LinkedIn: https://www.linkedin.com/in/sushil1 Skypeid: mrsushil24

Mechanical Engineering

Manufacturing, Industrial and Commercial Sectors

USA B1 VISA valid till 2020

Facilities Management Project Planning & Execution Budgetary Controls Design

Equipment Repair & Maintenance Civil / Structure CMMS ERP Piping

KEY ACHIEVEMENTS

Over 17 years of experience in Engineering, Operations and Project Management

Recent successful completion of Rod Yard Shed Project

Conception and execution of various big and small projects within strict budget & timeframe

Planning & execution of various cost saving activities without investment in house.

Chairman & key driver for Energy Saving Committee.

Key member & contributor of safety committee.

Within 2 months of the 2011 flood in Thailand, enabled production by restoring primary machines which had been submerge by up to 3 meters of water; remaining machines were fully operational within additional 5 months; plant size 360,000 SQM (approx. 500 Machines)

Damaged caused by flood was extensive; saved $200K USD by fabricating a one-of-a-kind tank hood to melt chilled Zinc (120 MT) while still in tank; OEM said couldn’t be done

Saved $.43 M in production costs (350 MT) by replacing damaged cooling coil of a 7 m lead bath without emptying molten lead; production did not stop during replacement

Reduced maintenance delays from 11% to 1% per month thereby increasing the mill availability; utilized various cause and effect tools to determine chronic failures

Increased productivity from 20 MT/hr to 44 MT/hr over a 30-day period

Selected and fast-tracked for 46-member leadership team out of 5,000 candidates

As management key person in Union meetings and negotiations.

PROFESSIONAL EXPERIENCE

Usha Siam Steel Industries PLC, Thailand May 2011 – Present

(A division of the Usha Martin Group; a large ISO-9001 accredited plant with an

annual manufacturing capacity of 36,000 MT. An MNC with locations in India, UK, Dubai, Bangkok, USA, Australia, Singapore, Africa)

Senior Manager – Engineering, Operational Maintenance & Projects (Department Head)

Led all Mechanical /Civil / Structural / Electrical Projects, of a 360,000 SQM steel wire and steel rope production facility with a reporting team of direct & indirect 50 employees

Responsible for working with safety for all projects and maintenance jobs.

Responsible for maintaining all operational parameters for Furnace / Mill production.

Ensure good quality product by eliminating machine defect.

Heading PM pillar as a part of TPM activity.

Rod yard shed project of 2000sq m completed within a record time of 1 month.

Preparation of Monthly EIS detailed reports including detailed data analysis (MTBF/ MTTR)

Making Capital proposals with all detailing and targets

Negotiate in detail with vendors and price fixation for projects & spares

Import substitution of various spares and local spares development for cost management

Selection / change of material to make maintenance free life of spares and reliability

Understanding actual need of the project before finalizing the design and improvement

Risk Assessment for the project and process as required for any improvement / project

Maintained 500 machines with record-breaking down-time; kept preventative maintenance calendars and spares store to ensure pro-active maintenance

Established and monitored annual Engineering maintenance budget of approximately $50,000 USD; exercised budgetary controls

Implemented and maintained Total Productive Maintenance (TPM) pillars, Quality Circles, and ISO Systems

Recruited and supervised up to 50 staff within the engineering department; negotiated salaries, conducted annual performance appraisals, and provided on-the-job coaching; less than 15% attrition

JSW STEEL LTD., (Mills Division), India Nov 2007 – Apr 2011

(India's second largest private sector steel company with an installed capacity of

14.3 million MT per annum.)

Mechanical Manager

Led a green field project and managed all civil related roles to erect and commission a 0.6 km Wire Rod Mill with a 120 m/s production speed; Completed construction in Nov 2008

Consulted on the design layout, fabrication and erection of mechanical components including structural, equipment and fluid systems with engineering corrections of mixed gas pipe line for both wire rod mill and bar mill

Recruited and supervised entire project team (80 staff); provided on-the-job training/mentoring for safety and efficiency measures; Conducted annual performance appraisals and salary negotiations

Established and monitored annual engineering maintenance budget of approximately $10.2 M USD; exercised budgetary controls

Performed predictive maintenance using Temperature, Vibration and Noise Level Monitoring; prevented unexpected failures saving thousands per annum

Planned and executed maintenance activity on all machines and equipment; performed technical analyses of breakdowns to prevent repeats

Setup and established Pre-Finishing Mills / No Twist Mills / Reducing and Sizing Mills

Sustained mechanical spares inventory of complete Wire Rod Mill

Prepared Executive Information Sheets (department performance reports) and delivered technical presentations to help leadership improve decision-making

Maintained all ISO documentations

USHA MARTIN INDUSTRIES LTD., India Mar 2002 – Oct 2007

(The largest specialty steel plant in India and first to achieve TPM, with a one million MT

capacity per annum. An MNC with locations in India, UK, Dubai, Bangkok, USA, Australia, Singapore, Africa)

Assistant Manager, Mechanical Maintenance

As PM pillar leader, led the Productive Maintenance team of 60 and implemented proactive and preventative techniques to improve equipment reliability

Conducted preventive and predictive maintenance of equipment

Directed Reliability Centered Maintenance (RCM) analysis in conveyor section with a focus on preserving system functions

Conducted technical analysis of breakdowns to determine and resolve chronic issues

Performed condition based maintenance; Oil Testing, Temperature, Vibration and Noise Level Monitoring

Maintained ISO 9001-2000 / TS 16949 / ISO 14001 systems and prepared monthly Executive Information Sheets

Utilized BaaN ERP System to evaluate and streamline engineering operations

OTHER EXPERIENCE

NET LOGIC, India Dec 2000 – Jan 2002

(An internship/on-the-job training opportunity post-graduation of E-Commerce course)

Project

Completed a live project for NET LOGIC; used ASP & SQL to fill the online admission form and record all data submitted by applicants. Setup an auto-reply email for confirmation of applicants’ submitted form.

Course contents

C, C++, JAVA, XML, HTML, ASP, SQL DATABASE, VB SCRIPT

SIMPLEX ENGINEERING & FOUNDARY WORKS LTD., India Jan 2000 – Nov 2000

(An ISO 9001:2008 manufacturing company of equipment and spares for heavy industry)

Marketing Engineer

Studied schematics, measured, and gathered material requirements

Estimated cost of heavy steel castings with 32 MT capacity

Checked and confirmed machining of castings on shop floor

Assisted customers with purchase orders; provided answers to booking queries

EDUCATION & TRAINING

Bachelor of Engineering (Mechanical) 1999

Karnataka University, India

(With Distinction)

Machine & Material Handling

In-house, provided by Tata Robins Fraser

AutoCAD

IIS InfoTech Ltd.

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