Engineering Manager

Kalpesh Prajapati

Permanent Address: *, Yogeshwar Society – 1, Behind Nagalpur College, Mehsana, State – Gujarat, Country - India

Current Address: S5, 503, Smondoville, Electronic City Phase 1, Bangalore, Karnataka, India.

Contact: +919********* E-Mail: adduwq@r.postjobfree.com

SENIOR LEVEL ASSIGNMENTS

Maintenance & Operations ~ Engineering & Project Execution ~ Erection and Commissioning

SNAPSHOT

Engineering professional with 19 years of experience in Engineering & Maintenance of Plant Machinery & Utility, Project Execution, Erection & Commissioning and Team Management.

Presently Associated with Biocon Pharma Ltd. (Generic Formulation OSD Plant) as Dy. Manager (Engineering & Maintenance) at Bangalore.

A keen individual with excellent interpersonal, analytical, troubleshooting and team building skills with proven ability in establishing quality systems / procedures and planning / managing resources. Significant exposure in SAP, AutoCAD, ISO 9001, Manufacturing Excellence activity, cGMP, Kaizen, 5s.

CORE COMPETENCIES

Operations & Maintenance

Planning and implementing predictive / preventive / shutdown maintenance schedule for machinery so as to increase machine up time and equipment reliability.

Implementation of Energy saving activity. Optimum utilization of resources.

Scrutinizing the hidden cost like overtime hours, extra duty hours – reducing it by proper planning.

Implementing systems & procedures to reduce rejection levels and ensure compliance with the industrial quality standards preparing for maintenance department.

Identifying areas of obstruction / breakdowns and taking corrective measures / steps to rectify the equipment.

Planning budget, Inventory control & maintain the stock of critical spares.

Cost saving by local development.

Modify the existing design to increase the machine efficiency and reduce the breakdown.

Involvement in the Customer, Local Authorities and the Regulatory Audits and complying observation.

Demonstrate and Train to employees to improve the efficiency, quality and performance which is value addition for company. Identify the training needs for department employees for better result.

Ensure timely completion of statutory requirements. Maintaining the documentation related to GMP, Safety, Quality and Environment.

Engineering & Projects

Concept note Preparation and Bar chart Preparation of the Project

Detailed BOM Preparation for the Project and Purchase Requisition

Technical Discussion with the Vendors for equipment selection

Vendor finalization and document review

Planning of erection work

Work distribution to the team and Technical guidance to the erection contractor

Review Project Progress and ensures the timely completion of the Project

Commissioning, Performance testing and handing over to the operation team

Review all the documents of DQ, IQ, OQ and PQ.

Quality, Health & Safety, Auditing

Maintaining quality standards for incoming materials, ensuring stringent adherence to quality standards, norms & practices. Ensuring productivity and quality improvement by Manufacturing Excellence system, Kaizen, 5s, Why Why analysis, GMP, CAPA, etc, Coordinating execution of plans and imparting quality Awareness Training.

Statutory Compliances like EOT, Hoist, Lift, Pressure Vessels, Safety valve testing (Form 9, 10, 11), Validation and qualification of equipments, Liasioning work related to UGVCL etc.

Ensuring safety compliances.

EMPLOYMENT NARRATION

June 2018 to till date at Biocon Pharma Limited, Bangalore (Generic Formulation)

As Dy. Manager – Engineering & Maintenance

Company Overview

Biocon is India's largest and fully-integrated, innovation-led biopharmaceutical company. As an emerging global biopharmaceutical enterprise, It serve customers and partners in over 85 countries and committed to reduce therapy costs of chronic diseases like autoimmune, diabetes, and cancer.

Key Result Areas

Equipment and System Handling :

Taking care of the Engineering and Maintenance for the OSD generic formulation facility.

Handling of process and packing equipment

RMG, Fluid Bed Dryer, Tablet Compression, Coating, Capsule filling machine, blister packing line, Bottle packing line, Blending, Sifting, LPD, Pass box, Dynamic Garment Cubic, Isolator, Autoclave, De duster, Scrubber, etc.

Handling of Utility and Facility

Purified water system, Hot water generator, HVAC system, Chiller, Compressor, Cooling Towers, Air Dryer, Clean rooms, Cold Rooms, AHU, etc.

Taking care of QMS for engineering, Timely closing of CAPA and Deviation, Preparation and review of SOP, Change Control, History card, Check list, Communication Memo, etc.

Implementation of All necessary Procedures and Preventive Maintenance Programme for the Equipment. Follow the OEM Guidelines to make the equipment Performance according to the design.

Responsible for the Periodic validation of the System and equipment.

Responsible for 24 x 7 for any major breakdown.

Coordination with all necessary departments like Production, Process engineering, Quality, Ware House, Purchase, etc. for the all engineering related functions.

Implementation of the required tools and Techniques to improve the work Practices like Predictive Maintenance, MTBF, RCFA and Many others.

Preparation of the Revenue and Capex Budget for the Engineering Section and tracking of the expenses of the same.

Preparation of BOQ base on P&ID, layout and actual site condition.

Fabrication and erection of piping, structure and equipment.

Participate in the Customer, Local Authorities and the Regulatory Audits.

Budget preparing, maintaining critical spares, Vender development.

Handling of New project and facility expansion.

Send the inquiry, negotiate and finalize the Vender for required spares.

EMPLOYMENT NARRATION

September 2015 to February 2018 at Biocon Sdn. Bhd. Malaysia

As Dy. Manager – Engineering & Maintenance

Company Overview

Biocon is India's largest and fully-integrated, innovation-led biopharmaceutical company.

Key Result Areas

Equipment and System Handling :

Taking care of the Engineering for the API Facility. Ensure that the Systems for the Smooth running of the Plant are in Place and maintains its standards without any deviations.

Handling of the Process Equipment.

50KL Fermenters (Reactors), Tanks, Autoclaves, Freeze Dryers (Lyophilizer), Agitators, Crystallizers, Centrifuges, Filtration Skids, CIP Systems, SIP Systems.

Handling of the Utilities

Purified Water System- RO and EDI, Storage Tank and Distribution System, Pure Steam Generation and Distribution System, Water for Injection Generation and Distribution System.

Chillers, Air Compressors, Nitrogen Plant, Raw Water System and Softners, Cooling Towers, Air Dryers, HVAC System and Clean Room Equipment.

Handling of 63nos AHUs catering to Various Classes like CNC, Grade A, B,C and D. Ventilation System, LAF, Dynamic and Static Pass boxes, Isolators, Bio Safety Cabinets, Exhaust Units, etc.

Responsible for all engineering activities, preventive maintenance, breakdown maintenance, facility management, spare part management, employee and equipment safety.

To execute the project as per Job planning and scheduling on daily and weekly basis to meet project target.

Supporting and providing resources during plant commissioning and ensure timely rectification of points identified during commissioning.

Vender development, Spare management and Budget preparation.

Handling of the required all documentation as per cGMP requirements.

Participate in the Customer, Local Authorities and the Regulatory Audits EAMA, USFDA, ANVISA, COFEPRIS, NPRA, MHRA.

Identify the Bottlenecks situation and take the corrective measures like modifications or changes as and when required improving the Productivity.

April 2014 to August 2015 at Piramal Glass Ltd, Jambusar, ( Bharuch )

As Dy. Manager – Engineering

Company Overview

Piramal Glass Ltd is one of the largest manufacturers of glass Bottles for the pharmaceuticals, Cosmetics perfumes, Food and Beverages. It is among the top five manufacturers of perfumery bottles in the world.

Key Result Areas

Equipment and System Handling :

Taking care of Engineering and Project Department which includes the activities related to plant machinery, Utilities and other Engineering services.

Responsible for the supply of the Smooth engineering and Maintenance related services without any interruption.

Leading the team of the Engineers and other down line employees in effective manner so that the optimum utilization of the available resources can be achieved.

Responsible for the implementation of the modifications, improvements and necessary changes required time to time to achieve the targets of the business and improve the Productivity and efficiency.

Carry out the Preventive actions on time to avoid any Production loss, Utility loss or the any other losses related to facility.

Maintain the Critical Spares and Inventories to ensure the smooth running of the equipments.

Implementation of the Ideas for the Energy Saving, water saving and other Utilities Savings.

Preparation of the Annual Maintenance Budget, Energy Budget and the Capex Items Budget.

Maintain the Quality of the Utilities which are required for the product.

Responsible for the Statutory Compliances related to the Engineering department.

To maintain the Breakdown history and its trend to take the appropriate actions.

Coordination with the various departments like Purchase, QA and Production for the Engineering related requirements.

Preparation of the Performance Presentation for the Engineering department and forward the same to higher management.

To maintain the documentation related to ISO-9001, ISO-140001 and OHSAS-18001 and facing its Periodic audits.

Equipment Handle : Utility & Plant Machinery : Compressors, Pumps, Cooling Tower, AHU, Air Conditioning System, Softening Plant, R.O. Plant, D.M. Plant, Submersible pumps, Vacuum pumps, Centrifugal Blowers, D.G. Sets, Forklifts, Material Handling Equipments, ETP, Multi Effect Evaporator, Annealing Lehr, Batch Charger, Stirrer, Bucket Elevator, Conveyors, PHE, etc.

March 2012 to April 2014 at Anil Limited, Ahmedabad

As Dy. Manager – Engineering

Company Overview

Anil Limited is the FMCG base company and it is leading manufacturer of Starch and Its derivatives. They have also state of the art facility for Manufacturing of Dextrose Powder, Liquid Glucose. Also involved in the manufacturing of Calcium Gluconate. It is the largest supplier of Starch and Glucose for the domestic and International Market.

Key Result Areas

Equipment and System Handling :

Taking care of Corn Wet milling plant including Engineering and Project Department which related to plant machinery, Utilities and other Engineering services.

Coordinating with all cross functional departments.

Increasing the productivity by modification and development

Reducing cost by local vender development.

Demonstrating and training given to down line team to improve the work quality and efficiency.

Equipment Handle : Rotating & Stationary Equipment, Centrifugal Pumps, Course Grinder, Baur Mill, Maize Vibrators, Mercone, Dorr clone, Merco, Rotary steam Dryer, Spin flash Dryer, Sparkler Filter, Crystallizer, Furnace, Tripple Effect Evaporator, Steeping Vat, Silos, Tanks, Bucket Elevator, Screw Conveyors, Centrifuge machine, Maize Cleaning m/c, Dewatering Press, Agitators, Rotary Air Lock Valves, etc.

March-2002 to February 2012 at Bisazza India Pvt. Ltd. Kadi (Italy base company)

As Manager – Engineering

Company Overview

Bisazza India Pvt. Ltd. is the Glass base Multinational Company (Italy). It is one of the largest manufacturer of GLASS MOSAIC TILES used on floor & wall.

Key Result Areas

Equipment and System Handling :

Taking Care of the Engineering and Maintenance of the Plant which includes the activities related to Mechanical, Electrical, Instrumentation and other Engineering services. Responsible for the Planning and execution of the Maintenance and Engineering activities. Lead the team of the Electrical, Mechanical Engineers and down line engineering employees. Responsible for the day to day activities related to Engineering and Maintenance, Coordination with the Production, Quality assurance to upkeep the Smooth running of the Production and Implementation of the Systems. Implementation of the new ideas and techniques to improve the system in terms of the efficiency, quality and cost controlling.

Equipment Handle : Utility: Compressors, Pumps, Cooling Tower, Softening Plant, Chiller, R.O. Plant, Submersible pumps, Vacuum pumps, Centrifugal Blowers, D.G. Sets, Forklifts, Material Handling Equipments, Hydraulic Equipments, etc. Furnace: Stirrer, Batch Charger, Electric Hoist, Crane, Forming m/c, Annealing Lehr, Weight loss feeder, Screw charger, Heat Exchanger, Gas reversal System, Gas fired Burner. Batch House: Mixer, Aspirator, Material Handling System, Gyro screen, Crusher, Magnetic Separator, Bucket Elevator, and Pneumatic Material Charger. Papering Department (Packaging): Papering m/c, Box packing m/c, Net gluing Machine, Oscillating Machine. Gas Station: LPG and Propane Storage Tanks 30Ton, Fire Fighting System, Unloading Pumps, and Gas Vaporizer, Gas line, regulator, Burner, Safety shut off valve, Filters.

Major Attainments in Plant

Utility department:

oReplaced number of pumps by single pump.

oImported vacuum pumps replaced by Indian water ring pumps to reduce the imported spare parts.

oIn forklift reduce the break down cost by authorized servicing and using original spare.

oReduced pneumatic problem by installing air drier and auto moisture drain system.

oAttained reduction in scaling problem by installing softening plant and dosing system of water treatment chemical.

oManufactured material handling equipment.

oCompleted the expansion project with in time period. Before the Start of the Project activities, Prepared the bar chart for the activities to be carried out as per the timeline of the targeted period for completion, execution for the planning for the sourced required to avoiding any delay in the project activities.

oSaved energy in Cooling tower, Centrifugal Blower, Compressors.

Furnace (Continuous and Day Tank)

oDesigned and installed of the Gas train and Burner.

oDesigned the Heat exchanger for reduce the gas consumption by using flue gas from chimney

oImprovement in designing of stirrer m/c, which results in improved mixing of glass color.

oImprovement in designing of charging m/c, which results in, reduced charging time.

oManufactured & modified forming m/c, forming belt and water jacket system of furnace.

oReplaced the motorized system by pneumatic system for distribute the tiles in the Annealing Lehar.

Batch House:

oCrusher m/c.:- Installed new modified & higher capacity dust suction system & aspirator.

oBatch Mixer: - Changed the door opening position so not necessity the conveyor Belt.

oInstalled and commissioned the Magnetic separator and magnet Bank for remove the iron particles from Batch.

oPut the scraper for cleaning the conveyor rollers.

Papering m/c:

oReplaced mechanical system by pneumatic system and reduced the breakdown hrs.

oReplaced mechanical system by A.C. drive and reduced the Breakdown hrs.

oUsed wear resistance conveyer belt reduced the breakdown hrs and cost.

oReplaced the Bearing by spring in eccentric vibrating table.

March 2001 to February 2002 at Hitachi Home & Life Solutions (India) Ltd. at Kadi

As Trainee Engineer

Company Overview

Hitachi Home & Life Solutions (India) Ltd. is one of the largest manufacturer of Air conditioner, Chiller and Refrigerator.

Key Result Areas

Equipment and System Handling:

Working in Coil shop production department

Ensure the smooth and trouble free performance of VBHB M/c, Fin Press, Coil Bending M/c, Hot air Oven, Leak test apparatus, Material Handling Equipments, etc with minimum break down time and optimum efficiency in Coil Shop production Dept.

Planning for overhauling the machines with maintenance dept.

Maintaining the records of daily production.

Coordinating with Stores and Purchase Department to maintain minimum inventory.

ACADEMIC CREDENTIALS

Diploma in Mechanical Engineering from K.D. Polytechnic, Patan in October 2000 with first class.

B- Tech in Mechanical Engineering as correspondence course From Karnataka State Open University in August 2014 with first class.

I.T. SKILLS

SAP, ERP, MS Office, AutoCAD and Internet Applications.

PERSONAL PROFILE

Date of Birth 1st Jun 1981

Linguistic Abilities English, Hindi and Gujarati

Expected Salary Negotiable

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