Maintenance Plant

Rishi Kochar

****, ********* **** **, ****, NC **518

E mail: *************@*****.**.**

Mobile: 919-***-****; Office: 919-***-****

Executive Brief

Over 21 years of extensive experience in areas of Plant Maintenance & Plant Engineering Projects, in the Automobile Industry.

Associated with Sona BLW Precision Forge Inc as Sr. Manager Maintenance & Projects.

Assure equipment reliability to maximize production line productivity.

Implement process enhancements to improve efficiency and reliability.

Recommend design modifications to eliminate machine or system malfunctions and eliminate machine down time.

Expertise in creating Base for TPM thru 5S activity implementation.

TPM methodology adoption towards achieving 3 goals Zero Product Defects, Zero Equipment Unplanned Failures and Zero Accidents by identifying & reducing 7 losses (types of waste) (muda), namely set up and initial adjustment time, equipment breakdown time, idling and minor losses, speed

(cycle time) losses, start up quality losses, and in process quality losses.

Marshaled a culture of continuous improvement by way of reviewing processes and effectuating cost control measures to help the organization sustain operation amidst tough market condition.

Formulating budgets, ensuring proper asset management, supervising day to day work, generating various process reports for all the machines & lines.

Provides leadership to maintenance & production team members to take care of plant assets thru CLIT methodology.

Thru cross functional team of Maintenance, Production & Engineering & in consultation of OEM develop

& maintain an effective preventive maintenance program (including repair, modification & installation of process equipment) to facilitate production efficiency & ensure optimal machine availability.

An effective communicator with strong leadership, people management, co ordination & analytical skill.

Conducting necessary review mechanisms audits for state, local & federal sponsored programs i.e. safety, environmental, and workforce control. energy conservation measures; ensuring product quality control as per various standards.

Leading and motivating workforce; imparting continuous on job training for accomplishing greater operational effectiveness/ efficiency.

Ability to interpret blueprints, manuals, & schematic drawings to facilitate repairs & aid in equipment troubleshooting.

Area of Strength

Maintenance & Utilities Facility Engineering Cost optimization Project Planning & Execution Budgeting & Cost control Erection & Commissioning Sourcing/Vendor Dev. Material/Store Mgmt. Inventory Control People management Manufacturing Innovation Continuous Improvement 5S Lean Management Productivity improvement

TPM Daily Work Management KRA

SMED Cycle time reduction Kaizen

Experience

Sona BLW Precision Forge Inc: Sr. Manager Maintenance & Project 1 Oct 2013 – Present

Manage overall plant maintenance activities.

Design, evaluate, install, operate and maintain mechanical products, equipment, systems and processes to meet plant requirement, applying knowledge of engineering principles.

Confer with other engineers or personnel to implement/revise operating and maintenance procedures and resolve system malfunctions to improve equipment reliability, safety, productivity, quality & cost. .

Understand and support work in accordance to all ISO/TS/QS standards and supporting documentation.

Recommend design modifications to eliminate machine or system malfunctions and eliminate machine down time.

Coordinate material & manpower planning with full utilization of MP2 (maintenance operating system), planning & execution of maintenance/engineering tasks, with full documentation.

Conduct research that tests or analyzes the feasibility, design, and performance of equipment;

Investigate equipment failures and difficulties to diagnose faulty operation, and to make recommendations to maintenance crew.

Specify system components or direct modification of products to ensure conformance with engineering design and performance specifications.

Supervise the erection & commissioning of machines & equipment in co ordination with Projects & Engineering departments.

Coordinate material, support & manpower planning for daily, weekend & shutdown activities & projects.

Supervise & coordinate maintenance of plant equipment such as:

Band Saw machine & Shear of Schubert.

Mechanical Presses of Eumuco & Ajax, Manzoni, Smeral,

Hydraulic presses (up to 630 ton) of Diffenbatcher, Lasco & Sack & Kiesel batch Germany.

Induction heaters (up to 1100 KW) of CEFI, Ellotherm, Elind & Ajax Tocco.

Tunnel, Conveyor & Tumblast type Shot Blasting Machines.

Seal Quenched batch type Heat Treatment Furnaces.

CNC Turning Centers from Moriseiki, Kitako, Mazak, Emag & Fuji etc.

GPM & SPM controlled by CNC, PLC, Hydraulic & Pneumatic.

Automatic Broaching machines.

Utility M/c’s including Air Compressors, FDV, Cooling Towers, High Bay Cranes and Pump House etc.

Undertake spares planning and retrofitting of the equipment.

Sustain inventory at an optimum level to prevent wastage as well as ensure cost savings.

Manage stores in line with best practice guidelines

Manage the breakdown of equipment within the targets.

Cost reduction thru vendor development, material management & inventory control.

Lead and motivate workforce; imparting continuous on job training for accomplishing greater operational effectiveness/ efficiency and Communicate with strong leadership, people management, co ordination & analytical skill.

Directly manage three supervisors and a maintenance team of approximately 25 employees. Amtek Group Companies, Gurgaon / Dharuhera, as A.V.P. Maintenance Oct’09 till Sept 12

Reporting to Plant Head & Leading Team of 25.

Deliverables

Maintenance Management

Planning, Scheduling & Executing Preventive & Predictive maintenance practices to maximize plant availability.

Identifying, Initiating and implementing various measures for effectively curbing maintenance time & mean time between repairs for critical equipment’s. Project Management

Managing innovation including Capital & Capacity Planning.

Formulating budget for complete project; performing ROI / PBP assessment.

Conducting feasibility studies for determining project viability. Putting in place project plans consisting of budgets, work plan, capacity planning & resources needs.

Inviting quotes / offers from vendors & evaluating them to choose most beneficial one.

Getting the capital equipment’s (VMC/CNC/HMC/SPM/GPM) developed at vendor end on time including prove out.

Supervising the erection & commissioning of machines & equipment as per stipulated instructions. Plant Engineering

Effectuating policies / plans for maximizing machine uptime.

Detecting faults / defects in machines/ equipment’s & rectifying the same.

Maintaining an optimum inventory (Inventory Control) & Stores Management.

Sustaining inventory at an optimum level to prevent wastage as well as ensure cost savings. Managing stores in line with best practice guidelines.

Sourcing material from diverse sources, identifying the most cost effective one for procurement. Bharat Forge ltd., Pune, as A.V.P. CDFD Maintenance Oct’07 Oct’09

Reporting to Executive Director & Leading Team of 30. Distinctive Attainments

Overall handled maintenance activities of CDFD division.

New Shed along with Vertical storage of Dies Planned, Budgeted, Designed, Procured, Installed and Commissioned. (2007 2008): 5 crores.

Facilitated the development of various special purpose machines for automating production of various components which includes handling automation by feeders, conveyors, pick / place units, transfer of components between operation for various applications.

Facilitated in achieving better process reliability and quality by changing manufacturing process flow operation sequence and by technical analysis to eliminate the recurring problem with conceptual skills.

Visited Germany for sharing & presenting various Continuous Improvement Projects with 6 group companies.

Adeptly managed waste elimination including process waste & saved large amounts from different implementations like process simplifications, manpower savings, productivity improvements & other savings.

Improvements done in the manufacturing of forgings and machined components for automotive applications such as Crank Shafts, Front Axle Beams, Steering Knuckles, Connecting Rods. Sona Okegawa precision forging, Gurgaon, as Senior Manager Maintenance & Projects Aug’97 Oct’07

Reporting to Managing Director & Leading Team of 35. Deliverables

Leading & managed Predictive & Preventive maintenance of equipment, planning and executing predictive / periodic / preventive maintenance; effectuating policies and ensuring compliance with the same.

Implementing measures for curbing downtime and breakdown duration & frequency.

Undertaking spares planning and retrofitting of the equipment.

Distinctive Attainments

Member of Core Team from Plant’s Green field stage. Played a stellar role in initial total Plant set up including utilities & Plant Machineries for 02 no’s forging press lines of 800 & 400 Ton capacity

& Heat treatment shop involving Equipment selection, procurement, Installation, Commissioning & handover to production.

Involved in initial Product & Process development for Precision forged Bevel Gears & Pinions for 4 wheelers.

Further independently Designed, Planned & Executed state of art of Single piece flow forging line of 400 ton & 300 Ton Capacity using Servo driven Friction Screw Presses.

Made significant contribution towards the development of low cost automation and also helped in the conversion of manual operations to semi automatic. This resulted in reducing time by 15% cost savings by about INR 20 lacs.

Altos India Ltd., Gurgaon, as Junior Engineer Maintenance Sept’95 July’97

Reporting to Maintenance Head.

Deliverables

Working hands on in attending Breakdown / Preventive maintenance of plant machinery. Distinctive Attainments

Member of Core Team from Plant’s Green field stage. Played a stellar role in initial total Plant set up including utilities & Plant Machineries for SMT line for PC’s motherboard manufacturing. Technical purview

CNC (Fanuc) Friction Screw forging Press (up to1250 Ton) ENOMOTO Japan. Screw Type presses (16000 Ton) Muller Weingarten Germany. Mechanical Presses of Eumuco & Ajax.

Reduce Roll Machines. Eumuco.

Hydraulic presses (up to 1000 Ton): ISGEC India.

Angular head Grinder: Micromatic grinding technologies. Induction heaters (up to 800 KW) & Oil fired furnace for billets / stock heating. Multitable, Inline, Hanger type & Tumblast type Shot Blasting & Shot Peening m/c’s from Indabrator, Pangborn, Sufis Klenz & Disa.

Seal Quenched, Bogie, Continuous Type Heat Treatment Furnaces. CNC Turning Centers from HAAS USA, Takisawa Japan, ACE Machines, Lokesh Machines & LMW machines. Various GPM & SPM controlled by CNC, PLC, Hydraulic & Pneumatic. Broaching, Circular Saw Cutting & Band Saw Cutting Machines. Utility M/c’s including D.G. sets, Air Compressors, Water Softening Plants, FDV, Cooling Towers, EOT Cranes, and Pump House etc.

Academics

B.Tech in Mechanical Engineering from IASE Rajasthan University. 2007

Diploma in Mechanical Engineering from G.B. Pant Polytechnic, Delhi. 1995 Computer Proficiency

MS Project, MS office, SAP, AutoCAD, Internet. Computer skills with Microsoft Office (Outlook, Excel, Word and PowerPoint) SAP, MP 2.

Training Courses Attended

Hydraulic system troubleshooting, commissioning & maintenance by Yuken India Limited and ISGEC, Yamunanagar.

Commissioning and Maintenance of D.G. sets by Cummins.

Maintenance of various Production Machines like Forging Presses, Shot blasting Machines etc. Commissioning & Maintenance of Friction Screw Pneumatic forging presses by Mitsubishi Materials Corporation Japan for 20 days.

Planned Maintenance by CII by Mr. Yamaguchi.

Workshop on QS 9000 organized by CII. 3 days.

CNC Operation & Maintenance of Grinding Machines at Micromatic Grinding Technologies Ltd. 1 week.

Kaizen Workshop by CII. 2 days.

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