Summary
Overview
Work History
Education
Skills
Accomplishments
Technical Skills and Training
Timeline
Generic

GANESH KUMAR

Puducherry

Summary

To leverage over 25 years of extensive experience in mechanical maintenance, production, and project management to contribute to a forward-thinking organization. My goal is to enhance productivity, optimize processes, and ensure high standards of quality and safety. I aim to utilize my expertise in troubleshooting, quality control, and TPM implementation to support organizational objectives while maintaining a strong focus on time management, safety, and discipline in a dynamic and stimulating environment.

Overview

30
30
years of professional experience

Work History

Plant Maintenance Engineer

Amway India Enterprises Pvt Ltd
Madurai
09.2015 - Current
  • Food Processing & Nutrition Equipment: Experienced in maintaining and troubleshooting various machines including IMA tablet fillers, PACE unscramblers, HARLAND labeling machines, and high-speed pouch packing systems. Proficient in TPM activities and implementing lubrication systems.
  • Quality Control & Documentation: Managed IQ, OQ, PQ documentation, and successfully completed quality assurance audits. Skilled in TPM practices and spares management.
  • Soft Gel Equipment: Handled encapsulation, gel preparation, fill preparation, capsule inspection, and sort mats.
  • Soap Technology: Managed soap production equipment and operations, including wrapping machines, stampers, extruders, and hydraulic mills. Experienced in troubleshooting and shop floor integration.
  • Troubleshooting: Proficient in troubleshooting a variety of machines and systems, including tablet fillers, labeling machines, and online coding systems.
  • Material Handling: Experienced with equipment like forklifts, reach trucks, and stockers.

Senior Maintenance Technician

Hindustan Unilever Ltd
Pondicherry
09.1997 - 09.2015
  • Wrapping Machines: Skilled in operating and troubleshooting WRA ACMA, and KHOSLA wrapping machines, with capacities ranging from 160 to 550 TPM.
  • Stamping and Mixing: Experienced with BSM soap stampers (2.8 tons per hour) and Z' Arm Sigma mixers (600 kg per batch), as well as Ploughshare and Shear Mixers (3000-liter capacity).
  • Extruders and Blenders: Proficient with PLOODERS twin-worm extruders and various blenders, including TOTE, KONTA, and V-Blender.
  • Hydraulic and Pneumatic Systems: Knowledgeable in TRQ hydraulic mills (500 and 2000 PSI), air compressors, vacuum pumps, chiller plants, and Roots blowers.
  • Packaging and Filling Machines: Expertise in IMA tablet filling, PACE bottle unscramblers, HARLAND labeling, high-speed pouch packing, ALL-FILL powder filling, and FOWLER ZALKIN capping machines.
  • Material Handling: Experienced with HOPT, forklifts, reach trucks, stockers, and BOPT equipment from Linde & Nilkamal Ltd.
  • Troubleshooting: Adept at resolving issues with various machines, including PSMs, chill drums, multi screws, online coding machines, and more.
  • Plant Operations: Basic operation of DFA plants and integration of shop floor lines for auto line operations.

Act Apprenticeship Trainee

Bharat Heavy Electricals Limited
Trichy
10.1994 - 10.1995
  • Maintenance & Troubleshooting: Skilled in maintaining and troubleshooting food processing and nutrition equipment, including various high-speed filling, labeling, and packaging machines.
  • Quality Control & Documentation: Experienced in handling IQ, OQ, PQ documentation and managing quality assurance certification audits. Implemented TPM activities and lubrication systems on the shop floor.
  • Spares Management: Proficient in managing spare parts for a wide range of equipment, including tablet and capsule machines, packing and capping machines, and blenders.
  • Material Handling: Experienced with equipment such as forklifts, reach trucks, and stockers.
  • Soft Gel Equipment: Knowledgeable in handling encapsulation machines, gel preparation, fill preparation, and capsule inspection.

Education

Diploma In Mechanical Engineering - Mechanical Engineering

Rajasthan Vidyapeeth University
Rajasthan
01.2010

I.T.I - Fitter

Govt. I.T.I
Cuddalore, Tamil Nadu
10-1993

S.S.L.C -

Govt. High School
Tamil Nadu
01.1993

Skills

  • Maintenance Planning
  • Hydraulic systems
  • Operations Management
  • Maintenance
  • Cost Estimation
  • Root Cause Analysis
  • Equipment maintenance and repair
  • Continuous Improvement
  • Lockout and tagout procedures
  • Inventory Maintenance
  • Pneumatic Systems
  • Conveyor Systems
  • Equipment Troubleshooting
  • Technical reporting
  • Component Replacement
  • Preventive Maintenance
  • Personal Protective Equipment

Accomplishments

  • Successful Installations: Completed the installation and commissioning of various lines and machines including double head VFFS powder pouch, hair oil filling line, sachet powder filling line, and jump back screw lift machine.
  • Operational Improvements: Enhanced production efficiency by designing an auto case packer, implementing a quarter line operation, achieving zero breakdowns in soap wrapping machines, and adapting machines for large pack sizes.
  • Engineering and Maintenance: Commissioned multiple chiller plants, overhauled essential machinery (mixers, mills, BSM, RAL, PSM, chill drums, roots blowers), and installed a laser coding machine.
  • Awards and Recognition: Received the WOW Award and Sporkle Award at Amway for outstanding contributions.
  • Training and Development: Attended specialized SME training and prepared a technical training center for mechanical, electrical, and pneumatic systems.

Technical Skills and Training

Technical Skills:

  • Diploma in Office Management
  • MS Office: Proficient in Excel, PowerPoint, Word
  • System Documentation: Experienced with Impower and Infor (Hexagon) systems for maintenance and stores management
  • Lubrication Systems: Skilled in implementation and documentation, including mapping and standardization
  • Technical Training Center: Prepared training for mechanical & electrical drive systems, pneumatic systems, tools, bearings, and fasteners
  • Visual Control Systems: Developed and implemented

Training:

  • Safety and Emergency Response:DU PONT Safety Workshop
    Fire Fighting Workshop (USHA FIRES)
    First Aid (National Safety Council)
  • Operational Excellence:5S Training
    TPM Program Level-1 (JIPM)
    OEE Improvement Workshop
    Good Manufacturing Practice (GMP)
    Good Documentation Practice (GDP)
  • Specialized Technical Training:Hydraulic Training (Festo Institute, Chennai)
    Basic Mechanical Training (Bearing, Lubrication)
    Defensive Driving (Hindustan Unilever Limited)
  • S.M.E. Training:Fasteners & Hand Tools, Power Transmission, Bearing & Maintenance Management, Pumps & Valves, Basic Electrical (T.V.S Training Service)
  • System Training:IMMPOWER and HEXACON INFOR Systems (Work orders creation & completion)

Timeline

Plant Maintenance Engineer

Amway India Enterprises Pvt Ltd
09.2015 - Current

Senior Maintenance Technician

Hindustan Unilever Ltd
09.1997 - 09.2015

Act Apprenticeship Trainee

Bharat Heavy Electricals Limited
10.1994 - 10.1995

Diploma In Mechanical Engineering - Mechanical Engineering

Rajasthan Vidyapeeth University

I.T.I - Fitter

Govt. I.T.I

S.S.L.C -

Govt. High School
GANESH KUMAR