Plant Maintenance

SUBRAMANYAM NAIDU SANDRA

Plot No. **, *nd Floor, Samatha Nagar,

Opp. JNTU, Kukatpally,

Hyderabad - 500085

Mob: +91-949*******; Email: *****.******@*****.***

Graduate in Electrical Engineering with 20+ years of experience in Maintenance, Erection & Commissioning, TPM and Energy Conservation activities Electrical Construction activities. Project Management, Contract Administration, etc. in reputed organizations like MRF Limited, JK Fenner India Limited etc.

Key Competencies and Skills

Planned Maintenance and Predictive Maintenance.

TPM (Total Productive Maintenance). Served as an Active Member for Autonomous Maintenance Pillar.

Trouble Shooting & Breakdown Maintenance of Plant Equipment including utilities

Energy Conservation Activities.

Familiar with MTBF MTTR, Why-Why Analysis Techniques.

Expertise in Data Management - Maintenance of Master data and History cards of plant equipment.

Good in shop floor manufacturing practices like PDCA, SMED, 5’s, KAIZEN, POKA YOKE, SGA Etc.

Layout Changes and Re location of machinery. Familiar with AutoCAD.

Erection and commissioning of new Equipment.

Liaison/ Coordination with Statutory Authorities like Electrical Inspectorate, Inspectorate of Boilers and Pollution control Board etc.

Spares inventory Management and control.

Budget Monitoring and Analysis for Spares, Repairs & Maintenance and consumables

Monitoring and controlling KPI.

Familiar with AutoCAD 2005, certified from CITD, Hyderabad

SAP PM Module Post implementation support & Training

Project Management

Contract Management and Administration

Academic Credentials:

B.Tech in Electrical Engineering - from Andhra University, Vishakhapatnam with First Class

Diploma in Electrical Engineering from S.V Govt. Polytechnic, Tirupati with First Class

Course on AUTOCAD from Central Institute of Tool Design, Hyderabad

Course on Lead Auditor – ISO 14001 by TUV Nord, Hyderabad.

Course on Internal audit for ISO 9001-2000 (QMS) by TUV

Course Time Management by Manicoms Institute of Mangmnt, Hyd.

Job Role and Responsibilities

Present Role: M/s Opus Industries Pvt. Ltd., Kodad, Telangana - As Factory Manager from April 2019 to Till date

To lead production planning from the market objectives and ensure that production happens on time and as per plan

To ensure that volume production targets during season and non season is as per plans

To plan the resources for production in relation to costs and productivity norms. Raw material planning,

Optimizing the cost of production and reduction of Rejection and rework

Managing all Preventive, Predictive and Breakdown maintenance activities of Plant and Utilities.

Managing Operation & maintenance of all production lines like SCADA based automatic Mixers, Silos, Automatic cutting lines, Tilting cranes, Auto Claves, Packing Cranes and related utilities and Achieving the planned production targets with minimum downtime.

Managing Operation and Maintenance of Plant utility includes Boiler, Chilling Plant, Air Compressor DG sets, Cooling tower, AHUs, Power Distribution system and other.

Scheduling and planning predictive, preventive and breakdown maintenance jobs through various check lists and why-why analysis under Total Productive Maintenance.

and also ensuring the work through TPM.

Implementing KAIZEN and OPL at regular basis to improve the line/plant efficiency and skill of the permanent and operators.

Training of Operators on autonomous maintenance activities, Conducting Brain storming sessions on equipment problems and equipment improvements.

Ensuring all equipments in the line are operated as per the rated capacity, minimal break downs & good Mechanical Efficiency

As Sr. Manager – Projects in M/s Abir Infrastructure Pvt. Ltd. - April 2011 to April 2019 - 8 Years for

Project Coordination for 5000 Cr., 2 x 600MW Singhitarai Thermal Power Project, Chhattisgarh.

Execution of Electrical works for 800 Crore, 1.44 Million Cu.m Storage terminal at NOCL Refinery project under construction at Cuddalore, Tamilnadu.

Responsible for the complete Execution of Electrical works for Oil storage terminal with Contract administration & Materials, project progress monitoring,budget monitoring,Cost control and Procurement management.

Responsible for Execution of construction of 3 switch houses with Power & Distribution Transformers up to 2.0 MVA, Lighting Transformers, VCBs, Power and Distribution panels. Total Electrical Works to the tune of Rs. 45 crores.

Laying of 400 kms of HT and LT Cables

Installation of 11.0 mtrs High mast Lighting Etc.

Review of specifications for Thermal Power Plant and Oil refinery electrical equipment.

Review of Single line diagrams.

Review of vendor drawings.

Review of Equipment Layout drawings.

Review of Cable routing layouts.

Technical evaluation, review and finalization of Electrical works. Electrical Orders were finalized on L&T on Turnkey basis for Rs. 37.00 Cr.

Support for finalization of Instrumentation and Control system vendors. Total Instrumentation orders finalized for Rs. 42.00 Crores. Major instruments like Tank Gauging system, Level and Flow transmitters, Analyzers, Control Valves and Control system like DCS & FGS were finalized on Yokogawa, Honeywell, Chemtrol, Toshbro controls, Endress+Hauser, L&T Valves etc.

Conducting kick off meetings with vendors after issuing Orders, obtaining detailed project schedules from vendors, coordinating with vendors for submission of detailed engineering drawings and documents for engineering approval.

Co-ordination between Client, Engineering Consultants, Contractors & Sub-Contractors, TPI, Local Authorities etc.

Obtaining detailed project schedules from vendors, coordinating with vendors for submission of detailed engineering drawings and documents for engineering approval. Coordinating with HOD & vendors and replies to the queries and Vendor correspondence filing..

Progress reports: Maintaining Daily and Monthly Progress reports.

Verification and certification of Contractor’s invoices with respect to the actual progress.

To maintain latest copies of all drawings and documents.

Preparation of Project MIS

Conducting monthly review meetings with individual contactors along with site team identifying critical areas of concern and plan for the next stage.

Team building and bring in the culture of ownership.

As Asst Manager- Electrical at M/s MRF Limited, Hyderabad from July 2008 to March 2011 - 3 Years

Maintenance of fully automatic Mixing plant with SCADA having Ban bury 270 Liters and 620 Liters with auto batch system like Auto polymer, carbon, Oil handling system and pre compounding chemical weighing system.

Maintenance and trouble shooting of Dip Unit, 74” Calendar, Dual tubers and Mills in preparation.

Maintenance and trouble shooting of High Productivity SAMSON and Alwell Tyre building machines, Russian Tyre building machines etc.

Maintenance and trouble shooting of L&T and Devan Tyre curing presses

Maintenance and trouble shooting in PLCs and VFDs up to 440 KVA in LV and 3.3KV 1900 KVA water cooled AC Drives.

Maintenance of Transformers up to 2.5 MVA Resin filled Dry type and protection relays (ABB REF610)

Operation and maintenance of 132 KV Substation with a capacity of 132 KV/11KV, 25MVA and 20 MVA ONAF Transformers and associated Switchgear.

Operation and Maintenance of Utilities like DG Sets up to 2MVA, Air Compressors up to 750 cfm, Steam Boilers up to 25 T, Room air conditioners and Pumps etc.

Monitoring the performance of machines through Why- Why Analysis and Daily check lists of critical Machines.

Planning and execution of preventive maintenance activity.

Energy saving/ Cost Reduction Projects planning, execution/implementation and review of savings.

Formulating the Operations budget for Utilities like Power& fuel, Consumables, spares, Repairs & maintenance cost

Formulating the CAPEX(Capital Expenditure) Budget

Lead the maintenance team in achieving budgeted targets like Specific Consumptions of Power & Fuel and Down Time etc.

Relocation of Machines, Layout preparation, material planning and execution of Up gradation

projects, installation and Commissioning of New machinery.

Responsible for implementation of ISO 9001 – 2000 activities in department.

Well versed with management system tools like 5S, Kaizen, TPM, SGA

Post implementation support to PM module in ERP – SAP R/3 implementation.

Commended and recognized on numerous occasions for delivering positive results.

Significant Achievements

Reduced down time from 8.0 % to 0.8% in Mixing Plant during 2008-09 in MRF.

Reduced Plant 2 Tyre scrap from 21 tyres/Month to 4 Tyres/Month during 2009-10 and headed towards Zero tyre scrap.

Maintaining Zero Breakdown in Auto lines like Calendars, Extruders and Dip unit.

As Asst Manager- Maintenance at M/s Fenner (India) Limited, Hyderabad from July 1999 to June 2008 - 9 Years

Maintenance of Plant equipment like K4 Mixer, Mixing Mills, Extruders, Rota Cure Machines, Profile Building Machines, Flipping and Sleeve cutting machines, Automatic Oilseal curing presses and Utilities like DG Sets up to 750 KVA, Air Compressors up to 750 cfm, Steam Boilers up to 3T, Thermic fluid heater up to 2.0 lac K Cal, Vapor Absorption Chilling Plant, Room air conditioners and Pumps etc.

Making break down analysis and 5 why analysis and analyzing the root cause of the problem and taking precautionary measures.

Energy saving/ Cost Reduction Projects planning, execution/implementation and review and auditing of savings and publishing the savings throughout the plant and rewarding to motivate the employees.

Post implementation support to Plant Maintenance Module module in ERP – SAP R/3 implementation.

Analysis of Breakdowns, spares, repairs & Maintenance cost through SAP.

Responsible for the Layouts preparation and finalization, Project estimations, and equipment selection of green field Auto Belts project value of about Rs 500 million

Responsible for the erection and commissioning of the plant and machinery

Liasoning with the suppliers and consultants for the timely execution of the projects

Layout changes, re-location for the above machinery.

Formulating the CAPEX(Capital Expenditure) Budget and Operations budget for Utilities like Power& fuel, Consumables, spares, Repairs & maintenance cost.

Significant Achievements

Reduced Specific Consumption of Power from 2.28 to 1.51 Units/ kg of Production during 2001-07, Specific Consumption of Fuel from 0.37 to 0.27 Liters/kg of Prodn.

Reduced the breakdowns percentage drastically to 1.0% from 5% by implementing PM activities, monitoring the critical equipment performance, following time based and condition based maintenance and using the latest information technology tools like SAP.

Received a cash award and appreciation letter from President and director for energy conservation activity.

Participated in the competition of 1st National Convention on Energy Conservation in 2005 at Vizag and received commendation award.

As Sr. Engineer- Plant Engineering at M/s Metropoli Overseas Limited, Bangalore

from January 1996 to June 1999 - 3 years.

Erection and commissioning of Process equipment like Ball Mills, Latex Mixers, Homogenisers,4 Stage & 2m width Nylon conveyors, Acid bath conveyors, Packing machines etc. for Latex threads manufacturing plant imported from Germany with Distributed control system.

Erection and commissioning of Utilities like Boiler 1T, DG Sets 360 KVA, Chilling Plants, Pumps etc.

As Production officer – Maintenance at M/s Techtran Poly Lenses Limited, Hyderabad

From July 1991 to December 1995 - 4 Years.

Maintenance of Process equipment like Mould making machines, Robotic Mould cleaning machines, Mould assembly unit, Lens Brushing machines, Leens cutting machines, Lens Grinding machines for Hard Resin Ophthalmic Lens manufacturing plant.

Maintenance of Utilities like Cold storage rooms, DG Sets 250 KVA, Chilling Plants, High pressure Hot water Pumps etc.

As Maintenance Supervisor at M/s Agarwal Rubber Pvt. Ltd. Hyderabad

from August 1987 to June 1991 - 4 years

Maintenance of Plant equipment like, Mixing Mills, Extruders, Tube Curing presses, and Utilities like DG Sets up to 250 KVA, Air Compressors up to 300 cfm, Steam Boilers 1T, Room air conditioners and Pumps etc.

Technical Skills

MS Excel, MS Power Point, MS Word, AUTOCAD, SAP PM Module.

Personal Details

Date of Birth : 16.07.1968

Marital Status : Married

Languages Known : Telugu, English, Hindi, Tamil and Kannada

Passport Details : K5561952, Valid till 21.01.2023

Present CTC : 8.4 Lacs/annum

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