Manager Maintenance

Shankar Narayan Pawar

E-Mail: *******.******@*****.*** ~ Contact: +91-992**-***** / 976**-*****

SENIOR MANAGERIAL ASSIGNMENTS

MAINTENANCE .

CAREER ABSTRACT

Versatile, accomplished & goal-oriented professional with around 26 years of experience in Production Management and Operations & Maintenance. Presently associated with Kalyani Technoforge Ltd.as a Plant Sr.Manager- Maintenance.

Kalyani Technoforge is TPM JIPM A CLASS Awarded, part of USD 3.0 billion conglomerate Kalyani Group under Bharat Forge as the flagship Company. Engaged in the manufacturing of World Class Forged & Machined products for various Auto and Non Auto Segment Customers, the Satisfaction. company is committed to adhering highest standards of Excellence, Quality and Customer.

Actively involved in handling the Production, Maintenance, Quality, Store operations, Tool management, Purchase and Administrative functions.

Exhibits a strong and firm approach to sustain & encourage safe work environments and a demonstrated ability to streamline operations. Applies continuous improvement principles to increase process, Maintenance efficiency and company profits. Expertise in handling project execution, implementing plans & schedules for maintenance & annual turnaround with focus on optimum utilisation of manpower and materials.

Proven track record in implementing cost saving measures to achieve substantial reduction in terms of raw materials, manpower and machine utilisation. An effective multi-cultural communicator with strong analytical, problem solving and organizational abilities.

CORE COMPETENCIES

Working out production requirements with respect to utilities, machines, manpower and monitoring overall operations for ensuring timely completion.

Managing production with safety along with compliance of environment and 5s in order

Monitoring implementation & documentation of quality systems, managing techno-commercial activities relating to O&M contracts and procurement of utility equipment.

Effecting preventive maintenance schedules of various kind of equipment to increase the equipment uptime / reliability and accomplishing project targets.

Implementing safety techniques at the plant and effectively reducing rejections in the shop and line layout .

Dealing with OEMs, Vendors, Architects & Contractors and monitoring expenses with optimum utilization of resources.

Directing & instructing Maintenance Technicians; arranging training for O&M Personnel on regular basis to maintain equipment in healthy condition.

Handling the design, integration & modifications of Utilities System, facilitating the up-gradation and troubleshooting of utilities

Setting of KPI for different departments and Man power planning for entire operation

Applied Concept of lean manufacturing, cost reduction, INVENTORY MANAGEMENT IN MANUFACTURING PROCESSES.

Independently Managing the Plant maintenance, Reconditioning, Plant Engineering.

Energy Conservation Audit and implementation of TS16949:2009 & OHSAS 18001:2007 system.

Electro pneumatic Presses, Oil fired and Induction heaters, Electromechanical, Power

Electronics. CNC machines of various kinds having Fanuc controls.

P.L.C(Siemens simatic S5-150s,S7300,Allen Bradly, Messung etc) troubleshooting & Modification in ladder programming, SCADA System maintenance & troubleshooting of Lectrotek make Lectroposs system, Hydro-pneumatic equipments .

Plant Automation & installation of soft starters, Utility equipment such as Atlas make scerw type compressor’s maintenance & Installation, commissioning of energy saving equipments such as Real time power factor panels & improvement of power factor. Liasioning with Govt. agencies like M.S.E.B.& Electrical Inspection authority.

Focusing on Bottleneck operations in the plant and arranging preventive and corrective action.

Cost control with respect to repair, inventory control, annual budgeting. Costing for Power, Fuel, Engineering expenses. Spare maintenance system and resuscitate consumption of spares.

Vindicating ISO-TS documents, Petty works, Breakdown analysis, TBM, CBM, History Card, TPM, SOP and Purchase requisition.

Target towards zero breakdown via root cause analysis and 6-W2H analysis.

Machine capacity planning of shop to ensure delivery of products to customer

Maintenance/Operations

Heads Maintenance Department and leads the Project & Maintenance activities in plant

Installation & Commissioning of 1000T,2500T & 4000T Forging press automated line with Robots by following all safety norms and supplier recommendations.

Analysis and identification of root cause of problems and horizontal deployment of solution to other areas of Engineering

Maintenance of plant machinery (CNC, VMC and other SPMs on Fanuc Control) and Utilities.

Preventive, Corrective & Breakdown Maintenance of Machines.

Cooperates with other departments, in providing assistance to solve problems and for Continuous Improvement in plant. Leads continuous Improvement Projects related to Quality, cost, delivery & Productivity.

Works as part of Advanced Product Quality Planning (APQP) team to ensure flawless launch of New Products without fail and highest productivity.

Responsible for Spare Part Management of machines and Budgeting of the expenses in department.

Ensure that proper records are maintained and reports monthly reducing trends of expenses, breakdowns and non conformities.

Manage and improvement of preventive/ predictive Maintenance system of the plant leading to zero breakdown

Responsible for performance management within the department through employee personal business plan, training & effective discipline.

As a competent supervisor it is your responsibility to adhere to the company's occupational Health and Safety policies, regulations and ensure that all subordinates should follow safety precautions leading to zero accident.

Advise a worker of the existence of any potential or actual danger to the health or safety and provides assistance for zero accident.

Implementing and following various systems like 5S system, POKA-YOKA & KAIZENS in organization.

Machinery Spares Management- ensures availability & inventory control.

Preparation of Revenue Budget for Power, Repairs & Maintenance, Spares etc.

Kalyani Technoforge Limited. from April 2010 to till date as Sr.Manager Maintenance .

Overseeing production related tasks including planning, control and trouble shooting.

Setting up production targets and achieve the same within time and cost parameters.

Optimizing man & machine utilization to achieve pre set production targets.

Developing new process concepts for production optimization, yield improvement and developing guidelines for sequencing of manufacturing activities on the shop floor (SOP).

Support in Set-Up/Up-gradation, commissioning of new machinery/assembly lines thereby bringing profitability to the company. Minimizing performance bottlenecks for achieving high productivity with minimum consumption of material & machine and monitoring expenses.

Ensuring effecting preventive maintenance schedules of various machineries and instruments to increase machine up time and equipment reliability.

Proactively identifying areas of obstruction / breakdowns and taking steps to rectify the equipments through application of trouble shooting tools. Executing cost saving and energy saving techniques/measures and modifications to achieve substantial reduction in O&M Expenditures and work within the budget.

Work closely with quality personnel to review product consistency while monitoring scrap rates to determine trends and areas of improvement. Coordinate the hiring and training of all manufacturing personnel.

Monitor operation expenses and research ways to reduce costs while maintaining product quality.

Work closely with the Environmental Health and Safety Manager to ensure all members of the manufacturing team are aware of safety policies to provide a safe workplace for our employees.

Develop and execute the plant manufacturing budgets.

Conduct performance appraisals and provide coaching and guidance to all operations employees.

Remove production constraints; allocate human and equipment resources and direct production employees to attain all established goals.

Remove waste and constraints from the production process to improve efficiencies and enhance productivity.

Breakdown Analysis, maintenance team development through 5s, kaizen & tpm.

Errection & commissioning of new forging line-1000T,2500Tline, 4000T line with robot, CNC machines & PLC programming. 5s, kaizen,TPM implementation in shop floor.

Trinity Engineers Private Limited, Pune from Oct’ 2009 to March’2010 as Manager –Maintenance (Electrical & Mechanical)

Implemented the preventive maintenance schedules of various machineries to increase machine up-time and equipment reliability of Utilities, Heat Treatment shop, Machine Shop, Press Shop, etc.

Facilitated the indigenization of the spare parts.

Assured adherence to various quality standards such as QMS and EMS.

Distinguished the areas of quality failures and took steps to rectify the system.

Managed & responsible for day to day maintenance of CNC Machines, Induction furnaces, Oil Furnaces, Conventional machines & forging presses of 1000T & 1600 T (Russian )Capacity Alongwith 250KW to 800 KW Induction heater. 22KVA Substation, utilities like Compressors, EOT cranes etc.

Implemented ISO/TS 16949 System.

Looked after electricity saving by improving power factor & by rationalization of compressed air.

Liasioning with govt. agencies like, M.S.E.B., Electrical Inspection & Factory Inspector.

Negotiating with vendors for maintenance related jobs.

Endurance Technologies Private Ltd., Pune from Feb’2009 to Sept’2009 as Dy. Manager- Maintenance.

Handled continuous process plants day to day maintenance of melting furnaces controlled by Siemens Germany make PLC units S7-300, Various kinds of CNC machines having Fanuc controls,Heat treatment lines controlled by Messung make PLC units & Paint shop having conveyor lines controlled by Telemecanique make AC

Managed Drives & Conventional machines of tool room. 22KVA Substation, Transformers, utilities like Compressors, EOT cranes etc.

Kirloskar make D.G. set of 750 KVA with AMF panels & its routine maintenance.

Managed planning & implementation of effective preventive maintenance schedule in SAP system., so as to improve utilization of machines. Electricity saving by improving power factor & by rationalization of compressed air. Negotiating with vendors for off loading of maintenance jobs.

Budget preparation for maintenance & manpower cost reduction.

Amforge Industries Ltd. Chinchwad, Pune from Dec’1998 to Feb’2009 as Manager Maintenance.

Looked after the maintenance of Forging Presses, Induction furnaces, Oil Furnaces, Reducer rollers, CNC milling machines, Conventional machines of tool room and machine shop, 22KVA Substation, utilities like Compressors, EOT cranes etc.

Implementation of TS 16949 System.

PRECEDING TASKS

Patheja Forging & Auto Parts Mfrs.Ltd . Pune form Nov’1996 to Dec’1998 as Senior Engineer in Plant engg Dept.

Rajkumar Forge Ltd Chakan, Dist. Pune from Aug’1994 to Nov’1996 as Maintenance Engineer

Varsha Agro Plast (P) Ltd. Pune from Feb’1994 to Aug’ 1994 as Electrical Engineer.

Ensave Devices Pvt. Ltd. Electronics Sadan, Bhosari, from Feb’ 1993 to Feb’ 1994 as Production Engineer

SCHOLASTICS

B-Tech Electrical

Diploma In Electronics Engineering.

IT Skills :Well versed with Microsoft Office and Internet Applications.

PERSONAL DETAILS

Present Address : RH B2/8, Narayan Hut Housing Society, Jai Ganesh Samrajya, opp to Panjarpol, Bhosari, Pune-

411039

Date Birth : 17th Feb 1971

Maintenance & Operations

Erection and Commissioning

Procurement

Process Improvement

Techno-commercial Operations

Safety Inspection

Liaison / Coordination

People Management

TPM Implementation

Cost Reduction

Contact this candidate