Maintenance Manager Preventative

BIJU SWAMINATHAN

Palakkad, Kerala, India. email: *******@*****.*** Mob No: +233-*********, +91-906******* (H) email: *********@*****.***

Summary:

Result-oriented Maintenance Manager with 20+ years of experience in facility management, team leadership, and preventative maintenance protocols. Skilled at streamlining operations to increase efficiency and reduce downtime. Extensive background in various industries prioritizing correct execution of maintenance by enhancing overall productivity through improved maintenance strategies.

Highlights:

Plan and execute annual preventative maintenance schedules so that the annual set production targets can be met and plant efficiency and run ability are increased.

Responsible for all the predictive, reactive maintenance functions (electrical & mechanical), to achieve the up-time requirements on all machines and utilities.

To be a part of the management team and recommend and take the required measures, or make necessary modifications, to increase the efficiency of the plant.

Responsible for inventory management with a focus on capital investment and the returns on the same, focusing on cost and avoiding large inventories.

Responsible for the development, monitoring, and execution of the annual maintenance budgets. Also, ensure to minimize expenses within the approved budgets.

Responsible for maintaining a safe working environment ensuring the safety of team members, and taking necessary actions in case of any violations, works towards continual improvement and safety awareness.

Ensure that the utilities of the plant are effectively functioning and supporting the operations.

To ensure that the governmental regulations are adhered to, and environmental conditions are met without any deviations from the standards set by the municipality or other related authorities.

Hire, Train, and set the performance standards among the team members in coordination with the HR.

Evaluate and review all maintenance/engineering staff performance and establish a staff development plan beneficial to the department.

Responsible for spare parts management and ensures that critical spares are effectively managed based on availability vs. cost.

Skills:

Good knowledge to read and write in all types of schematics and blueprint diagrams (like Swiss, German, Italian, UK, and Turkey).

Excellent knowledge of PLC S7-400H control system with I/O Module, Profibus, Ethernet, Profinet, Wago, ASI BUS, and VFD.

An expert in new project handling and installation of industrial machinery and all electrical panels and equipment termination, I/O test, and commissioning.

An expert in problem-solving in mechanical and electrical base and PLC and MCC panel systems and comfortable with complex electrical system configuration techniques.

An expert in Hybrid solar power system Off/On-grid installation, commissioning, and troubleshooting.

Excellent working knowledge and root cause analysis of machine breakdown and solution (preventive and predictive maintenance) in Silos, Flour, and Feed Mills.

Knowledgeable in using SAP, MS Dynamic NAV2009, Microsoft applications, and basic programming.

Working Experience:

Maintenance Manager 11/2021 to Present

Takoradi Flour Mill Ltd, Takoradi, Accra, Ghana.

Working as a Maintenance Manager at the plant, which operates 3 wheat flour mills (Buhler, Satake, and Simon Robinson) on 2 plots with a daily capacity of 1100 MT.

Reported to the General Manager, I have 35 maintenance teams reported to me (including Maintenance Engineer, 4 Maintenance Supervisors, and 30 technicians).

Visited several Turkish-based milling companies, evaluated their machinery quality, and ordered several spare parts.

Worked as Acting Production Manager during the Production Manager's vacation.

Projects:

1.A &B Mill Upgrade: Buhler dump scales and roller mills (SATAKE) installed and commissioned. Roller mills were modified with an electrical control system to replace the old pneumatic system.

2.Machine shop: A new machine shop with all facilities was constructed and a fluting machine, sand blasting machine, compressor, and hoists were installed and commissioned

3.Mill C(Buhler) upgrade: The airlock system in the flour mill pneumatic line has been upgraded with additional PLC and sensors for speed monitoring, and installed plansifter monitoring sensors.

4.LV Panels Upgrade: Installed new Transformer (1250KVA) and LV panels upgrade with ACB and MCCB.

5.Solar Power Station: Installed 75 KW Hybrid Solar System with 150 solar panels, inverters, chargers, and lithium batteries with online monitoring system.

Maintenance Supervisor 10/2018 to 10/2021

Grand Mills, AGTHIA Group P.J.S.C, Abu Dhabi, UAE.

As a maintenance supervisor, I am handling the maintenance of two silo plants with two ship unloaders, three flour mills, Chakki, and Harees mills, two feed mill plants with five pellet mills, 15 packing lines, and all Facility activities.

Maintaining all utility sources (15 Transformers-related LV panels, Switchgear capacitor bank and harmonic filter,16 Compressor & and dryers, Fluting Machine, two Boilers (10 ton), and two Generators (Jengan 1500 KVA).

Working experience in BUHLER, ALAPALA, MOLINO, and CHAKKI flour Mills and Harees, Jareesh, & Hammer mills, and BUHLER and OCRIM feed mills.

Working experience in Buhler, Ehcolo, and Static Binder Palletizer and Wrapping machines.

Projects:

1.A Mill modification: Replaced the MOLINO roller mill and installed the latest ALAPALA roller mill and commissioned and gave training to operators and technicians.

2.Silo Pre-cleaning: Installed and commissioned Buhler drum sieves, bucket elevator, separator MTRC, Compi cleaner MTKB, MOZG.

3.C Mill upgrade: Installed and commissioned Buhler Purifiers, Impact detachers, blower, and vitamin feeder

4.Feed Mill fat coating line-2: Installed and commissioned fat coating conveyors and tank and interlock with the old system.

Electrical Supervisor 02/2017 to 08/2018

Oman Flour Mills Company (S.A.O.G), Muscat, Sultanate of Oman.

As an electrical supervisor, I am handling the electrical maintenance of the silo plant with two ship unloaders, two flour mill production lines (800 Ton/hour), 4 feed mill production lines, 10 packing lines, 4 palletizers, 10 tons 3 Boiler plant, Neuro and Buhler ship unloader, and all facilities.

Projects:

1.Roller mill Upgraded: Installed MDDQ roller mills, control panel, and cable termination and worked with Buhler engineers for I/O test and commissioning.

2.Feed Mill is upgrading: Installed chain conveyors, 4-Vibro Sieve MKZH, 2-packing line, and Mixer DFML control panels and terminated interlocked with the old control system and worked with Buhler engineers to I/O test and commission.

3.Palletizer upgrade: Decommissioned old palletizer and installed OCME (ALL GLASS Italy) Palletizer, control panel, and two Metler Toledo Metal Detectors

4.Bran Bagging: The bagging control panel of the Pagliarani unit was replaced with a new bagging control panel using a MEAG control unit and commissioned.

5.Pouch Packing: Installed pouch packing machine and commission.

Electrical Foreman 06/2009 to 10/2016

Saudi Grains Organization (formerly Grain Silos and Flour Mills Organization) Jeddah, KSA.

Seven years of working experience in BUHLER -Flour & Feed Mills and Silos as an Electrical Foreman.

Projects:

1.Flour packing upgrade: Decommissioned old palletizers and carousels and installed four Buhler Palletizers and Carousels and sewing machines and control panels.

2.Buhler Silo project: All automation, I/O test, and commissioning with Buhler Engineers for 128-Silos related machines, transferring belt conveyors from seaport with Vigan Ship unloader.

3.Buhler Feed Mill Upgrade: with new PLC control. Installed new Hammer Mill DFZK, Pellet Press DPBS, Countercurrent cooler DFKG, Bucket Elevators, Pellet packing line, and MCC panel control termination, I/O test, and commissioning

4.Installed FAWEMA packing, Pouch Packing, and two IMECO ROBOT Palletizing machines.

5.Decommissioned Avery scales and Installed three Precia Molen Truck Scales with new foundations.

6.C Mill Upgrade: Decommissioned old Buhler Mill and installed new Buhler Mill with WinCos system. Working experience with Buhler engineers.

7.The old silo mimic panel was modified to an automated PLC control system.

Service Engineer 02/2002 to 05/2009

Ashlyn Chemunnoor Instruments Pvt Ltd – Thrissur, Kerala, India.

All types of weighing scales (laboratory, platform, truck scales) services, professional installation, preventive maintenance, and user training on calibration.

Seminars and Training Attended:

1.Buhler Scherler-AG Engineers

Foreman for Feed Mill Upgrading, GSFMO Jeddah, Makkah Region, KSA -- June 2016.

2.Buhler Engineers

Silo Pro Plant User Training, Jeddah, Makkah Region, KSA -- June 2015.

Silo General Automation Training, Jeddah, Makkah Region, KSA -- June 2015.

3.YEAR

Fluting & sandblasting machines operation & mill rolls corrugating training and certification from YENAR factory in Turkey -Jan 2022

Education:

2001 Diploma in Electronics Engineering (3 Year)

Government Polytechnic, Palakkad, Kerala, India.

2001 Advanced Diploma in Java Programming (6 Months)

CSC Computer Education (P) Ltd, Palakkad, India.

I hereby certify that the above information is true and correct to the best of my knowledge and belief.

Respectfully,

Biju Swaminathan.

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