John Thomas Sundarraj

Managed various projects to ensure timely delivery and adherence to objectives. & Ensured adherence to regulatory requirements across all projects. (South Africa Regulatory Project)

• Defined project scope, objectives, deliverables, timelines, and success criteria for regulatory compliance initiatives.
• Developed and managed project schedules, tracked milestones, planned resources, and mitigated risks to ensure project alignment with regulatory requirements.
• Accountable for on-time project delivery, ensuring compliance with regulatory standards and contributing to overall project success.
• Collaborated with partners, customers, and key stakeholders to establish testing plans and long-term regulatory strategies.
• Initiated and managed new compliance programmes, driving stakeholder alignment and successful project execution.
• Prepared project documentation, compliance reports, quality metrics, process maps, presentations, and status dashboards.
• Monitored project performance, tracked deliverables, and provided regular updates to management and stakeholders.

• Led a digital transformation initiative in collaboration with global regulatory teams to implement an automated tyre sidewall verification system for Chennai and Indonesia manufacturing plants.
• Participated in an international workshop in France to gain expertise in global tyre regulations, compliance requirements, and industry best practices.
• Developed project roadmaps, implementation plans, and milestone tracking frameworks.
• Designed and developed a Minimum Viable Product (MVP) for automated tyre sidewall compliance validation.
• Coordinated with cross-functional teams to integrate the solution into R&D design tools, enabling regulatory verification in the early design stage.
• Provided regular stakeholder communication and progress reporting to ensure transparency and alignment.
• Improved compliance validation efficiency, reduced manual effort, and enhanced turnaround time and accuracy.

• Supported end-to-end planning and execution of new tyre line development projects across multiple manufacturing locations.
• Assisted in project budgeting, cost monitoring, and resource allocation activities.
• Coordinated global tyre shipments to international testing laboratories, ensuring compliance with regulatory and logistics requirements to facilitate timely testing.
• Managed test requests for safety, durability, endurance, and performance evaluations.
• Supported homologation and certification activities across multiple international markets.
• Collaborated with R&D, manufacturing, quality, logistics, testing agencies, and regulatory authorities to ensure timely project delivery.
• Facilitated effective communication and issue resolution among global stakeholders.

• Studied, interpreted, and implemented global automotive regulations and standards including AIS, BIS, FMVSS, ECE, GSO, and SASO requirements.
• Guided design and engineering teams on current and upcoming regulatory requirements throughout the product lifecycle.
• Conducted regulatory impact assessments and compliance reviews during product development.
• Delivered technical training sessions on regulatory updates and certification requirements.
• Reviewed technical drawings, specifications, and design proposals to identify compliance risks and recommend corrective actions.
• Collaborated closely with Design, Quality, Manufacturing, Testing, and Program Management teams to ensure product compliance.
• Managed Type Approval applications and certification processes for domestic and international markets.
• Planned and executed validation testing programs according to global regulatory standards.
• Analysed test results and provided technical solutions for homologation and compliance-related challenges.

• Project Management
• Facilitated homologation and certification processes for various products.
• Regulatory Compliance
• Led initiatives for new product development from conception to launch.
• Implemented digital transformation strategies to enhance operational efficiency.
• Managed relationships with global stakeholders to ensure project success.
• Coordinated activities among cross-functional teams for seamless project execution.
• Conducted product validation and testing to meet regulatory standards.
• Identified and managed risks associated with projects to ensure success.
• Managed type approval and certification processes for compliance.
• Monitored and implemented automotive regulations to ensure compliance.
• Identified opportunities for process improvement to enhance efficiency.
• Produced technical documentation to support compliance and project execution.
• Executed program activities to ensure alignment with strategic objectives.
• Coordinated international projects to ensure compliance with local regulations.

Supported vendor selection for machine dismantling and relocation projects by evaluating technical capabilities and project requirements.

• Planned and coordinated machine dismantling, packaging, and shipment activities to ensure smooth project execution.
• Guided dismantling teams on machine architecture, automation systems, and operational requirements, ensuring adherence to project specifications.
• Coordinated with international stakeholders, including the Mexico maintenance team, by sharing machine documentation and providing remote technical support for knowledge transfer.
• Calibrated, verified, and validated machines before shipment, ensuring compliance with operational standards and readiness for installation.
• Documented machine parameters, calibration records, and technical specifications for reinstallation and future maintenance support.
• Performed preventive, predictive, and breakdown maintenance on mechanical, electrical, and automation systems.
• Maintained production equipment including conveyors, welding machines, robotic systems, and utility equipment.

• Ensured maximum equipment availability while minimising downtime and production losses.
• Diagnosed and resolved PLC, automation, electrical, and mechanical failures.
• Conducted Root Cause Analysis (RCA) and implemented corrective and preventive actions.

• Improved reliability metrics including MTTR (Mean Time to Repair), MTBF (Mean Time Between Failures), and equipment uptime.
• Maintained and troubleshot PLC-controlled automated machines,Alen Bradley
• Supported HMI, VFD/Drive systems, and automation upgrades.

• Implemented process improvements to enhance automation performance and operational efficiency.
• Facilitated Kaizen and Continuous Improvement initiatives, leading to optimisation of manufacturing processes and enhanced operational performance.
• Improved Overall Equipment Effectiveness (OEE) and plant productivity.

• Implemented predictive maintenance strategies to reduce unexpected breakdowns.
• Managed utilities including DG sets, HVAC systems, fire protection systems, electrical distribution, and plumbing infrastructure.
• Monitored and optimised consumption of power, diesel, water, and other facility resources.

• Ensured uninterrupted operation of plant utility and facility services.
• Maintained maintenance schedules, equipment history records, breakdown reports, and RCA documentation.
• Utilised SAP/CMMS systems for maintenance planning, inventory management, and work order tracking.

• Prepared compliance documentation and audit-related reports.
• Coordinated with production, quality, engineering, and external vendors for maintenance activities.
• Led daily maintenance operations and supervised technicians during routine and shutdown activities.

• Supported plant shutdown, turnaround planning, and project execution.
• Ensured compliance with HSE (Health, Safety & Environment) standards and company policies.
• Followed LOTOTO (Lockout/Tagout), permit-to-work systems, and safety procedures for high-risk activities.

• Participated in safety audits, risk assessments, and continuous safety improvement programmes.
• Skills: PLC Programming | ABB Robots | FANUC Robots | HMI | SCADA | VFD Drives | Preventive Maintenance | Predictive Maintenance | RCA | Kaizen | OEE Improvement | SAP/CMMS | Facility Management | Automation | Industrial Maintenance | Team Leadership | HSE Compliance | LOTOTO.
• Performed PLC program backups for all machines, ensuring system data integrity and recovery readiness.

Skills: PLC Programming | ABB Robots | FANUC Robots | HMI | SCADA | VFD Drives | Preventive Maintenance | Predictive Maintenance | RCA | Kaizen | OEE Improvement | SAP/CMMS | Facility Management | Automation | Industrial Maintenance | Team Leadership | HSE Compliance | LOTOTO.

Executed maintenance tasks, improving operational efficiency through troubleshooting and root cause analysis (RCA). Created detailed documentation and reports, and coordinated maintenance efforts among team members to enhance workflow while ensuring compliance with safety standards.

• Performed preventive, predictive, and breakdown maintenance on critical mechanical equipment to ensure uninterrupted plant operations.
• Serviced and maintained pumps, compressors, conveyors, pipelines, and welding systems to support uninterrupted production operations.
• Planned and executed maintenance schedules to improve equipment reliability and operational efficiency.
• Implemented condition monitoring techniques and predictive maintenance strategies for early fault detection.
• Conducted Root Cause Analysis (RCA) for recurring equipment issues and implemented permanent corrective actions.
• Diagnosed and resolved mechanical failures through systematic troubleshooting techniques.
• Ensured maximum equipment availability while minimising downtime and production losses.
• Reduced equipment breakdowns by identifying failure patterns and improving maintenance practices.
• Monitored key maintenance KPIs including MTBF (Mean Time Between Failures), MTTR (Mean Time to Repair), and OEE (Overall Equipment Effectiveness).
• Collaborated with cross-functional teams to address and resolve critical production equipment issues, minimising operational disruptions.
• Analysed maintenance data and equipment performance trends to improve reliability and reduce maintenance costs.
• Drove continuous improvement initiatives to enhance plant productivity and equipment performance.
• Managed equipment documentation and tracked maintenance activities for performance analysis and regulatory requirements.
• Supported shutdown planning, preventive maintenance programs, and plant improvement projects.
• Guided technicians and contractors to ensure safe and timely execution of maintenance tasks.
• Facilitated effective communication across departments to minimise operational disruptions.
• Ensured adherence to Health, Safety & Environment (HSE) policies and company safety standards.
• Followed LOTOTO (Lockout/Tagout) procedures, permit-to-work systems, and risk control measures.
• Participated in safety audits, risk assessments, and corrective action implementation.
• Promoted a strong safety culture through compliance monitoring and continuous safety improvements.

Preventive Maintenance | Predictive Maintenance | Breakdown Maintenance | Mechanical Troubleshooting | Root Cause Analysis (RCA) | Reliability Engineering | MTBF | MTTR | OEE Improvement | Pumps | Compressors | Conveyors | Pipelines | Welding Systems | Shutdown Planning | Condition Monitoring | HSE Compliance | LOTOTO | Team Coordination | Continuous Improvement

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• Managed team of 10–12 technicians in unionised manufacturing environment, overseeing daily maintenance execution and optimising workforce planning.
• Planned and executed Preventive Maintenance (PM) and Predictive Maintenance (PdM) schedules, significantly reducing equipment downtime and improving reliability.
• Led maintenance and repair activities for extruders, trimmers, special-purpose machines (SPMs), and conveyor systems, ensuring maximum equipment availability and operational efficiency.
• Ensured timely restoration of equipment through effective troubleshooting and maintenance planning.

• Diagnosed and resolved mechanical and pneumatic system failures by interpreting technical drawings and pneumatic circuit diagrams.
• Conducted Root Cause Analysis (RCA) to identify recurring equipment issues and implemented permanent corrective actions.
• Enhanced equipment reliability through systematic fault elimination and proactive maintenance strategies, contributing to reduced unplanned downtime.
• Monitored equipment performance and implemented continuous improvement initiatives to enhance operational effectiveness.

• Supervised daily maintenance activities, including manpower planning, work allocation, contractor management, and technician skill development.
• Managed end-to-end procurement activities including purchase requisitions (PRs), vendor coordination, quotation analysis, and technical evaluation.
• Maintained optimum spare parts inventory using Oracle ERP, ensuring availability of critical components and reducing maintenance delays.
• Coordinated with suppliers and vendors to ensure timely delivery of components and adherence to quality standards, supporting uninterrupted operations.

• Prepared technical reports, performance metrics, and audit documentation to support operational excellence and compliance.

• Collaborated closely with production, engineering, quality, and external vendors to ensure smooth plant operations.
• Supported shutdown planning, maintenance projects, and continuous improvement initiatives.
• Enforced LOTO (Lockout/Tagout), permit-to-work systems, PPE compliance, and workplace safety standards.

• Achieved zero major safety incidents through strict adherence to HSE policies and proactive risk management.
• Participated in safety audits, hazard identification, and risk assessment activities to promote a safe working environment.
• Verified engineering drawings and technical specifications to support maintenance and project requirements.

Preventive Maintenance | Predictive Maintenance | Breakdown Maintenance | Equipment Reliability | Root Cause Analysis (RCA) | Pneumatic Systems | Extruders | Trimmers | SPMs | Conveyor Systems | Oracle ERP | Spare Parts Management | Vendor Management | Procurement | Manpower Planning | Team Leadership | Continuous Improvement | HSE Compliance | LOTO | Permit-to-Work System