GAURAV BHATT
UP
Summary
Highly analytical, performance-driven, results-oriented engineering professional with over ten years of experience looking to work for a company where my considerable abilities and expertise in plant maintenance, utilities, management, planning, and execution can be used to advance the company's objectives. Strategic manager with experience driving site-wide OEE and 'Vertical Start-ups' using TPM/RCA, Managing R&M budgets, and ensuring 100% uninterrupted utility operations and statutory compliance in high-speed bottling environments. Proven Technical Maintenance Manager with expertise in Predictive Maintenance, Root Cause Analysis, and Budget Control. Achieved 8% increase in plant uptime and 3-5% cost savings through innovative maintenance strategies.
Overview
3
3
years of professional experience
Work History
Technical Maintenance Manager
VARUN BEVERAGES LIMITED (VBL)
01.2023 - Current
- Led multi-disciplinary team of 30+ engineers and technicians to maintain all plant utilities, achieving 100% availability for blow-molding and process lines.
- Machine Availability: Increased overall plant uptime by 8% by transitioning from reactive to Predictive Maintenance using vibration analysis and thermography on critical rotary equipment.
- Utility & Energy Management: Optimized high-pressure reciprocating compressors (40 bar) and ammonia refrigeration plants, resulting in a 12% reduction in SEC per unit produced.
- Managed annual maintenance Opex/Capex budget, realizing 3–5% cost savings through indigenous sourcing and optimized inventory management in SAP PM.
- Reduced chronic breakdowns by 25% through implementation of structured 'Why-Why Analysis' and CAPA for mechanical failures in filling and capper systems.
- Compliance & Safety: Championed a 'Safety First' culture, maintaining 100% compliance with DSS+, PQA, and AIB International standards.
Education
B.Tech - Mechanical Engineering
UPTU
01-2015
Skills
- TPM
- Predictive Maintenance (PdM)
- Root Cause Analysis (RCA)
- Why-Why Analysis
- R&M Budget Control
- Capex Planning
- Spares Optimization
- ETP/STP Management
- SAP-PM
- Quality audits
- AIB Standards
- Regulatory compliance
- IBR Boilers
- Ammonia Refrigeration
- 40-Bar Air Compressors
- DSS
Key Performance Indicators
Reduced total power per case by monitoring Beverage and BM power to minimize the overall energy footprint., Maintained 78% efficiency by optimizing steam-to-fuel ratios and increasing condensate recovery., Delivered a 10% cost saving on compressor maintenance (HP, LP, & Refrigeration) by shifting from OEM to high-quality localized alternatives., Reduced 'Dead Stock' by 15% and ensured 98% availability of critical 'A' class spares in SAP PM., Minimized utility water Usage in utility process, saving 20–30 KL per day during peak season.
Digital Software Proficiency
IOT based system implementation to monitor Power consumption in respective areas., Expert user of SAP PM (Plant Maintenance) for work order management and SAP MM (Materials Management) for inventory & spares optimization., Proficient in AutoCAD for plant layouts, utility routing, and P&ID (Piping and Instrumentation Diagrams)., Skilled in MS Project for scheduling 'Vertical Start-ups' and plant commissioning timelines., Utilization of specialized software for Vibration Analysis and Thermography reporting.
Personal Information
Date of Birth: 04/23/94
Key Projects Energy Conservation
- Spearheaded the installation of a Low-Pressure Receiver (LPR) refrigeration circuit, optimizing evaporator overfeed and achieving a 2% reduction in total refrigerant charge and energy overhead.
- Spearheaded the installation of an IFC (Intelligent Flow Control) System, achieving a 5% reduction in high-pressure air energy consumption.
- Engineered and implemented an evaporative cooling solution, resulting in a 5% total energy saving for the refrigeration/cooling circuits.
- Installed a MAC (Master Air Controller) system to synchronize multiple compressors, delivering a 3% reduction in low-pressure air energy usage.
- Anchored the erection and commissioning of high-speed machinery to ensure a 'Vertical Start-up,' significantly reducing the initial plant cost-per-case.
- Engineered and implemented a water recovery system from pump seal cooling, successfully saving 15 KL of water per day.
Core Competencies
TPM, Predictive Maintenance (PdM), Root Cause Analysis (RCA), Why-Why Analysis, IBR Boilers, Ammonia Refrigeration, 40-Bar Air Compressors, ETP/STP Management, R&M Budget Control (18.5 Cr), SAP-PM, Spares Optimization, Capex Planning, DSS+, PepsiCo Quality Audits (PQA), AIB Standards, Statutory Acts
Timeline
Technical Maintenance Manager
VARUN BEVERAGES LIMITED (VBL)
01.2023 - Current
B.Tech - Mechanical Engineering
UPTU