GOPI KISAN GOPALA

1. Mechanical Maintenance 2. Electrical & Automation Systems 3. Instrumentation & Control 4. Utility Management 5. CMMS & Documentation 6. Safety & Compliance 7. Team & Vendor Management 8. Continuous Improvement & TPM

• Executed preventive and predictive maintenance plans for 120+ machines including CNCs, SPM , conveyors, hydraulic presses, and robotic arms
• Performed root cause analysis (RCA) of mechanical failures; successfully reduced unplanned downtime
• Managed critical spares inventory using ABC analysis, ensuring zero production loss due to part unavailability.
• Hands-on experience with alignment, balancing, bearing replacement, and overhauling of pumps and gearboxes.
• Led troubleshooting and maintenance of LT panels, VFDs, motors, and control circuits (star-delta, DOL).
• Diagnosed faults in Siemens and Allen-Bradley PLCs using ladder logic and HMI interfaces; improved fault resolution time by 25%.
• Implemented SCADA-based machine monitoring system across 3 production lines.
• Conducted insulation resistance testing (IR), earth resistance testing, and relay coordination checks as part of annual shutdowns.
• Supervised calibration of sensors (pressure, level, temperature) using standard equipment traceable to NABL.
• Installed and configured analog & digital instrumentation loops, performing loop checking and commissioning.
• Supported implementation of energy meters and data loggers for consumption monitoring and reporting.
• Oversaw operation and maintenance of utility systems:
  Air compressors (Atlas Copco)
  DG Sets (Kirloskar 750 kVA)
  HVAC chillers
• Implemented energy conservation measures, leading to a 12% reduction in utility cost through load optimization and VFD tuning.
• Maintained detailed breakdown history and preventive logs using SAP PM module.
• Generated daily, monthly, and annual MIS reports including KPIs like MTBF, MTTR, and equipment availability.
• Prepared and maintained Standard Operating Procedures (SOPs), work instructions, and maintenance checklists.
• Conducted toolbox talks and regular safety audits in compliance with ISO 45001 and Factory Act.
• Implemented LOTO procedures, hot work permits, and confined space safety protocols.
• Supported internal and external audits (PESO, Electrical Inspector, ISO, IATF 16949).
• Managed a team of 18 technicians and 4 engineers across three shifts.
• Coordinated with OEM vendors for AMC, spare supply, and warranty claims.
• Played a key role in new machine commissioning projects, including layout planning, foundation, and electrical wiring.
• Implemented Kaizens and TPM Pillars (Planned Maintenance, Autonomous Maintenance) – improved OEE by 7% across two critical lines.
• Led 5S implementation in maintenance store and machine areas, resulting in audit score improvement from 62% to 91%.

• Managed end-to-end automation projects including PLC programming, HMI design, robotic cell commissioning, and field instrumentation integration.
• Executed robot welding automation projects with FANUC, Motoman, and Panasonic robots, ensuring seamless integration with Mitsubishi PLCs and safety systems.
• Developed servo motor parameterization and implemented precise motion control algorithms for specialized manufacturing equipment.
• Performed troubleshooting using advanced diagnostic tools including oscilloscopes, logic analyzers, and software debuggers to minimize system downtime.
• Trained engineering teams on PLC programming standards, safety compliance, and best practices in maintenance of automated systems.