Maintenance Manager

G S PRASANNA KUMAR

Mobile: +968-******** (Oman) / +91-996******* (India) ~ E-Mail: ***********@*****.**.**

~ SENIOR / TOP MANAGEMENT PROFESSIONAL ~

MAINTENANCE PROJECT MANAGEMENT VENDOR RELATION With enriched experience of over 13 years in sectors of Automobile / Sanitary ware / Pharma Industry. Currently linked as Deputy Manager – Plant Engineering with Oman Ceramics, Sohar, OMAN

Career – At a Glance

Business Savvy Professional with rich and valuable experience in the Installation of Equipment’s, Maintenance & Project management. Expertise in implementing ISO 9001 quality management system, OSHAS 18001,EHS14001,TPM,TQM,TS16949 & Kaizens.

Dynamic Change-agent; Skilled in repositioning organizations in changing business scenario to achieve operational and service excellence through planning, prioritizing and mitigating risk while ensuring customer delight.

Growth oriented with proven results and repeated success in multiple projects and assignments handled. Driving vision and achieving critical and strategic goals.

An effective communicator with expertise in identifying & adopting emerging trends to achieve organizational objectives and profitability norms.

Proven expertise in boosting productivity, cutting costs and fostering efficiency in operations with proven track record in defining & observing process parameters, introducing process improvements & optimization, identifying and isolating areas of obstructions to ensure improve work quality, reduce unproductive activities and enhance overall operational efficiency.

Exceptional mentoring skills in transforming low performers to a high performing team through design & implementation of training programs for fostering keen customer focus, high energy levels and team spirit. MANAGEMENT SKILLS

Expertise in managing operations and ensuring overall equipment maintenance, quality standards, optimum utilization of the available resources etc. Expertise at handling the equipment efficiency,inventory function, and adherence to the minimum inventory level to minimize wastage. Results- oriented with the ability to coordinate multiple projects & teams simultaneously, coupled with the skill to effectively manage staff of all levels. PERSONAL TRAITS

Strong analytical and interpersonal skills. Organized and detail oriented to handle complex and dynamic business environment. Ability to develop and nurture strong working relationship with internal as well as external groups.

A Leader

Lead from the front, set up world class processes in the operation, build trust in working relationships and create open & frank working environment for teams, thereby motivating teams to achieve consistently improving results.

Decision Maker

Convert organisational goal into execution plan, setting stretched goal for self and team by promoting innovations, supporting changes and taking calculated risks to achieve targets.

Proficiency Matrix

Equipment and Machineries Maintenance Continuous Improvements Safety Management

Service Delivery Cost Control Project Management & Execution

Purchase Vendor Management Compliance & Quality Management

Spares Management Inventory Management System Implementation

Suggesting technical modifications in the existing systems for better functionality and productivity.

Looking after commissioning, Installation and replacement of machines as and when required and carrying out routine Inspection of machines.

Looking after availability and reliability of all equipment’s in plant including utilities.

Developing maintenance plan as per periodic / predictive maintenance studies for all equipment’s and plan for preventive action to avoid deterioration

Proficient in implementing improvements / Kaizens for critical problem techniques, executing preventive maintenance(TBM & CBM) and calibration of equipments to minimize equipment breakdown.

Checking the OEE for the equipments.

Oversee large scale engineering projects including management of external consultants.

Create prototypes, test functionality, develop specifications and qualify new designs.

Evaluate and implement mechanical engineering standards, best practices and procedures to ensure optimal performance.

Develop solutions to production problems related to materials, processes and tooling.

Collaborate with management to provide technical and engineering expertise for estimations and bid proposals.

Facilitate the development of technical documentation for accepted designs and assemblies.

Interpret codes, regulations and specifications to ensure compliance.

Negotiating price and purchasing engineering items from vendors, monitoring implementation of improvement initiatives to improve equipment

& machine availability and reduce cost of maintenance.

Taking preventive measures for machines to keep down maintenance cost as low as possible.

Attending various breakdowns occurring in site & giving spontaneous solutions thereby rectifying the problems and initiating kaizens to reduce.

Planning and Implementation of Projects within approved cost and schedule.

Monitoring and reporting of project progress, availability of men, material & machinery.

Preparing execution plans, reviewing progress against the plan, planning shutdown for project hook up and ensuring adherence to statutory compliances, quality and safety norms.

Planning, monitoring & controlling maintenance cost (spare, inventory, repairs and manpower) and optimizing cost within the assigned budget.

Planning & deploying manpower, assessing team performance, identifying training needs, measuring skill inventory and ensuring effective communication with executive & technicians.

Looking after commissioning, Installation and replacement of machines as and when required and carrying out routine Inspection of machines.

Looking after availability and reliability of all equipment’s in plant including utilities and Suggesting technical modifications in the existing systems for better functionality and productivity.

An efficient team leader and player with excellent communication, interpersonal, presentation, analytical, problem solving and team leadership capabilities

Expertise in implementing ISO 9001 quality management system, OSHAS 18001,EHS14001,TPM,TQM,TS16949 & Kaizens. Occupational Contour

Oct’13: Oman Ceramics, Sohar, OMAN

Deputy Manager / H.O.D. - Plant Engineering Dept.

Projects: Kiln Relining work, packing shed, new yard Interlocking system, Installation of Air compressor, Forklift . Plant shop equipment’s: Blowers, Ball mills, Blungers,Belt conveyor system, Hoopers, Stock arks, Bench casting, Beam Casting, Mannual casting, Pressure casting, Spary guns, POP plant, Stirrers, Monorail system, Shuttle kilns, Ware dryers, Mouldryers, Belt strapping machines, Logo machines,Walkbehind scrubbers,Vaccum machines, Docklevers, Blowdown fans, Hydraulic systems, Pneumatic actuators. Utilities: D.G. Sets, Air Compressors, Etp.

Material handling equipment’s: Forklifts, Shovels, Hydraulic Pallets, Stackers. Responsibilities:

Responsible for Maintenance department activities which includes Mechanical, Electrical, Instrumentation, civil and carpentry works including projects a per requirement.

Monitoring Energy, water, gas & air consumptions by various equipment, controlling utilization of contract manpower & overtime and reducing cost consumption by improving plant uptime.

Coordinating with contractors engaged for maintenance / project activities. Ensure delivery of agreed services with good quality and workmanship, Guide the contractors to carry out their activities safely.

Monitoring statutory compliance, maintaining compliance with standard maintenance practices, ensuring strict compliance of LC procedures before equipment shutdown and sharing knowledge with sub-ordinates.

Developing maintenance plan as per periodic / predictive maintenance studies for all equipments and plan preventive action to avoid deterioration.

Calibration of instruments like Pressure gauges, thermocouples, temperature indicators, vacuum gauges and weighing balance.

Facilitate maintenance jobs to Staff / Workers accommodation.

Maintenance of filters for all Blows down fans, Air compressors, DG set, Dust collectors, Air conditioning units, forklifts and Loaders.

Maintenance of Hydraulic and Pneumatic equipments.

Testing of the environmental & equipment w.r.t. Load test, Hyd. test, air pollution test, sound test and dust levels.

Ensure availability of critical spares for equipment maintenance in stores in order to reduce b/d and as well as cost.

Implementing PM schedule, monitoring implementation of jobs during shut down and solving plant maintenance problems w.r.t. MTTR and MTBF.

Improvements / Kaizens done w.r.t. in terms of PQDSM.

Ensuring implementation and review of ISO 9001 quality management system, OSHAS 18001 and EHS to improve plant working conditions, performance and quality standards in coordination with the employees.

Identifying & developing implementation of visual management (5 don’ts) improvement studies, new systems & best practices, awareness programmes, housekeeping activities (5S) and clearing NCRs.

Maximize the equipment availability by analyzing the breakdown trends, conducting root cause analysis (Why Why Why) & initiating kaizens to reduce.

Management Review Meetings

Planning for CAPEX and Budget for Plant Engg. Equipments.

Monitoring implementation of safety procedures, maintaining precaution through SOP,work instructions, warning signals, Lock-out/Tag-out and safety work permit system etc, analyzing accidents and taking corrective actions.

Training regarding maintenance of equipments to fitters / operators as per requirement.

Analyze machine downtime to identify and correct mechanical, electrical and welds related problems. Highlights:

Conversion of Pneumatic to electric accutators – Best ever kaizen made in the year 2015 in the company

Heat recovery system from kilns.

Pressure gravity tanks for spraying in glaze section and reduces mnt cost as well consumption of air.

Break down reduced w.r.t. previous years and reduced cost of maintenance .

Installation of gas flow meters in kilns,Energy meter and water flow meter in all production dept.

Maintenance related issues solved for getting certified in OSHAS 18001

Reduced water consumption through high pressure machines, break down reduced w.r.t. previous years and cost of maintenance.

Implemented PM module through SAP.

Achieved OSHAS 18001 certification for the company.

Productivity improvement interms of quality of the product in inspection booth by replacing manual water drain system to pneumatic pump. Mar’10 to Sep’13: Hindware (Hindustan Sanitary ware & Industries Ltd.), Hyderabad Deputy Manager

Projects: R.O. Plant – 10 Kl; Air Compressor of 525 cfm; Ware dryer Expansion; Kiln Plant shop equipment’s: Ball mills,Ball clay blunger, vigin blunger, Corresuel system, Monorail, Hydraulic systems, Tunnel KILN

(K19,K20 & K21 ), Bucket conveyor, Screw feeder,Vibrator chutes, Blowers,Sieves, Stirrers,Hoist, Roto Helical pumps, A.O.D. pumps, Submersible pumps, Stock arks, Exhaust fans, Spray guns, Waredryers, Three lobe compressors, Portable air compressors.

Utilities: D.G. Sets, Air Compressors, R.O.Plant, Thermairs. Material handling equipment’s: Forklifts, J.C.B.,Stacker,Hydraulic Pallet. Responsibilities:

Maintained plant & utility equipments, checked fabrication & welding job and managed overall activities related to erection, testing, commissioning and maintenance of varied electrical equipments

Handled basic engineering activities, designed layouts, prepared diagrams, charts, equipment list & technical specifications), monitored operating

& maintenance expense and maintained records as per audit requirements.

Analyzed troubleshooting & predictive / preventive maintenance functions, identified areas of obstructions and ensured reduction in machinery downtime to minimum.

Tracked purchase requisitions / purchase orders, maintained spares, monitored inventory level of spare parts, inspected all incoming materials and provided quality certification.

Implemented Kaizen, adhered to environmental policy, legal & other requirements, executed non-conformity, corrective & preventive measures and planned preventive maintenance to reduce breakdown time.

Allocated mechanical job to technicians, trained team members on SOPs & good engineering practices and ensured continuous improvement in quality, cost and operating/maintenance practices.

Worked with fabrication & civil vendor on daily job, prepared drawings and tracked jobs done by the Facility Management group and Plant Engineer for increasing individual efficiency.

PR and maintenance cost will be analyzed through SAP system. Highlights:

Ensured reduction of maintenance cost (bearings) through Kaizen and MTTR w.r.t maintenance cost .

Utilization waste air from three lob compressor to ETP agitation tanks.

Devised system for:

o Operational audits in terms of safety, good engineering practices & efficient jobs distribution. o Usage of all utilities & energy savings and ensured best energy efficiency in utility operations. Feb’07 to Mar’10: Mahindra & Mahindra, Hyderabad

Assistant Manager - Maintenance

Projects: Humidifier system, Softner plant,Water chiller, Air compressor. Paint Shop Equipments handled:

Pretreatment Hangers, Electro deposition Hanger, Hoists, Sealant pumps, Paint Pump, High pressure jet pump, Air supply fans( Centrifugal double inlet fan of both sides),Spray Nozzles, Full jet nozzles, Swivel pipe Clamp nozzles, Centrifugal pumps,Ovens, Hot air circulation fan, Sigle chain conveyor, Double chain conveyor, O Loop conveyors, Over head cranes.

Utilities:

Air Compressors: 1000 cfm of 4 nos.

Cooling: 90 TR of 2 nos. and 75 TR of 2 nos.

D.G. Sets: 1250 kva of 3 nos.

Water Chiller: 70tr of water cooled and 100tr of air cooled

Hot water generator: 1500000Kcal/ hr

D.M. Plant: 380 m3 / Regeneration

Softner Plant: 400 m3 /regeneration

Filter management: Taking of dust count level as per federal standard

Responsibilities:

Maintained paint shop and utility equipments, completed scheduled tasks and activities, ensured availability and reliability of all equipments including timely service delivery within quality & safety norms..

Conducted predictive maintenance studies for all equipments and planned preventive measures.

Identified and maintained requisite spares & consumables through local stores.

Developed maintenance procedure and work instructions for safe & reliable equipment operation.

Participated in safety & staff meetings and ensured compliance with the assigned procedures and systems.

Maintained cleanliness in work place adhered to 5S requirement and solved problems by using QC tools.

Executed various improvement projects to improve productivity, quality, delivery and safety.

Conducted hydraulic & ultrasonic testing for receivers and ensured timely closure of breakdown in SAP.

Coordinated, planned and implemented ideas to ensure energy saving and water saving.

Prepared documentation on preventive maintenance, break down (Why–Why Analysis), calibration, etc.

Ensure adherence to 5s,TQM,ISO14001,TSs1649 and TPM for the plant area.

Generated daily and monthly reports of utility section and raised purchase requisition through SAP. Highlights:

Reduced breakdown hours and frequency and ensured improvement in MTBF and reduction in MTTR.

Implemented TPM and delivered safety patrol rounds and awareness program to technicians.

Reduction of air consumption w.r.t. pressure.

Jan’05 to Feb’07: Arch PharmaLabs, Gurgaon

Maintenance Engineer

Plant shop equipment’s:– Reactors, Blungers, sieves, VTD, STD, Micronizer, Centrifugal pumps, AHU, Vacuum systems, SRP, Pressure filter,Lifts,Blowers,Blending machine,Multi mill,Mechanical filters. Utilities: - Boilers: 400 Kg/Hr and 850 Kg /Hr;Chilled Brine Compressors: Kc – 4 (23 Tr) and Kc - 6 (30 Tr);Water Chilled Compressors: Ac: 670 (40 Tr) and Vam (59 Tr);Air Compressors: 110 Cfm;Cooling Towers: 250 Tr, 150 Tr, 120 Tr and 100 Tr;Diesel Generators: 500 Kva and 200 Kva;Pumps: Centrifugal and Reciprocating, Demineralized Water Plant: 36 m3; Softner Plant: 90 m3 Instrumentation - Calibration of Pressure Gauges, Vacuum Gauges and Temperature Indicators/Gauges Responsibilities:

Handled routine & breakdown maintenance of static equipments in offsite / rotary machineries in the Utility Plant and participated in the erection & commissioning of various static equipments and rotary machineries.

Planned and executed preventive maintenance & calibration of equipments to minimize equipment breakdown.

Maintained minimum spares in the stores to reduce breakdown time.

Imparted training to the Operators / Fitters to ensure seamless operations.

Prepared Standard Operating Procedure (SOP) of various equipments.

Documented design, installation and operational qualification for new equipments.

Prepared preventive maintenance, breakdown & calibration records including reports of the Utility Section. Highlights:

Effectively prepared F.D.A. approved documentation and PM schedule.

Designed equipment and modified plant layout and P&I diagram of equipment’s by using Auto Cad 2000. Jul’03 to Dec’05: Vitalife labs (Apollo International Limited), Gurgaon Engineer / Trainee Engineer

Responsibilities:

Maintained plant equipments & utilities and including minimum/maximum spares as per requirement.

Purchased of general & maintenance items and conducted preventive maintenance of equipments as per schedule.

Prepared record as per audit requirement, created purchase order, MRN, etc. and ensured timely bill clearance. Highlights:

Prepared design of layout of plant and P&I drawings and collected data for ERP. Academic Credentials

2014 M.B.A in Safety and Six Sigma from IIBM

2003 B.E. in Mechanical from University of Madras

Personal Snippets

Date of Birth: 28th November 1978

Residential Address: Flat No. FF206, Abhinav Enclave, Balemvari Street, Ramarapadu, Vijayawada, AP, India Languages Known: English, Hindi, Telugu and Tamil

Passport Number: L3769692

Driving License: INDIA –DLFAP027134012007/ OMAN -96792764 Social Net Work

Skype Id : gsprasannakumar28

Watsapp: +919*********

Facebook: gsprasannakumar

LinkedIn: ***********@*****.**.** (https://www.linkedin.com/in/gsprasanna-kumar-071a7611a) Twitter : gsprasanna28

Employee Reference from Oman ceramics,Hindware,Mahindra and Arch Pharma Oman Ceramics - Oman

Mr. Puspakumara – Plant Technical Manager : +009********** - Email Id:******************@*****.*** Mr. Pawan Kumar Jain- C.F.O : +009********** – Email Id:*******@*****.*** Mr.Vish Natarajan – Ex.C.E.O. : +917********* - Email Id:**************@*****.*** Hindware - India

Mr. V.L.N. Murthy – Plant Coordinator : +919********* - Email Id:********@*****.*** Mr.Sudarshan – Store Sr. Manager : +919********* - Mahindra & Mahindra - India

Mr.Srinivasan –Store Manager : +919********* - Email Id : **********.**@********.*** Arch Pharma Labs - India

Mr. Baldevsingh Matharu –Maintenance AGM : +919********* - Email Id:********@**********.***

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