Kumaaravel K
Hosur
Summary
Mechanical Maintenance Engineer with 9.5 years of hands-on experience in engineering maintenance, production and project roles across industrial environments. Skilled in troubleshooting, preventive maintenance, and equipment optimization. Proven track record of reducing downtime, improving reliability, and maintaining safety standards. Seeking a dynamic opportunity to leverage my expertise and contribute to efficient plant operations.
Overview
10
10
years of professional experience
Work History
Maintenance & Project
Hindustan Unilever Limited
09.2022 - Current
- Company Overview: Coffee factory, Hosur.
- Overseeing all the equipment like Roaster, Extraction, Evaporator, ATFE and Spray Drier, Chiller, DHU, Cooling towers, compressors and Packing Machine like GP, AH, TT and 16/32.
- Monitoring the performance of the equipment and driving the energy efficiency initiatives to achieve the maximum performance.
- Planning and executing the Preventive maintenance, Condition based maintenance and Timebased maintenance in all equipment.
- Overseeing all phases of project execution; approve engineering/design changes, troubleshoot, and resolve Complex technical problems, consistently meeting project deadlines and highest possible quality standards.
- Structuring project plans, schedule of activities, budget, & cost estimates, planned, procured, mobilized, and deployed resources to deliver the projects within defined time and costliness.
- Formulating detailed budget for commissioning project, planned schedule of activities, mobilized resources - materials and manpower for successful execution.
- Maintaining production Logbooks and records for all audit purpose.
- Maintaining the process machinery's by doing routine PM.
- Responsible for maintaining the critical spare inventory at site and equipment classification.
- Unlocking the capacity of the equipment with less cost involvement.
- To ensure safe working environment by adhering to the safety norms.
- Involved in Implementations of GMP (Good Manufacturing Practices)/SOP (Standard Operating Procedures) at work for continual improvement in the Company.
- Led plant reliability, safety, and capacity enhancement projects.
- Partnered with production teams to identify savings through efficiency improvements.
- Collaborated with SHE team for safety/environment initiatives.
- Drove root cause analysis for equipment failures and implemented corrective actions.
- Championed Kaizens and autonomous maintenance through employee engagement.
- IC & CC silos systems installed and commissioned.
- Executed PAUT test for Ext B (1st time since 2011) with full maintenance cycle.
- Installed BQ Aroma system for Ext A, enabling aroma optimization and utility savings.
- Upgraded DPHE from 3 to 5-stage, reused MS line-saving ₹6L and improving energy efficiency.
- Upgraded Extraction TF Water Heater-₹22K/day savings and 23% thermal energy cut.
- Completed Extraction-A Automation Phase 2-100% auto valves integrated in SCADA.
- Unlocked 20% capacity in CC Coffee: BCT reduced by ~33%.
- Commissioned Biomass-based HAG-saving ₹1.5Cr/year, reducing 1180T CO₂.
- Conducted Fino fuel trials for roaster-cut costs, emissions, and boosted sustainability.
- Installed compact vibro sieve (1.2T/hr)-10% energy savings.
- Automated Rotary Filter & SRV valves-reduced ETP load by 250KL/yr, saved ₹28L.
- Improved Roaster output by 18.18%, CPT reduced by 3%, roasting loss down by 2.4%.
- Raised Spray Drier output from 960 to 1280 kg/hr by nozzle modification.
- Enhanced Pure Coffee Yield from 48% to 51%.
- Reduced Utility Cost by 9.13% (₹1.68Cr) via optimized extraction strategy.
- Spray drier Capacity unlock.
- Evaporator Capacity unlocking.
- Reduction of batch cycle time in Roaster.
- Twice awarded Unilever's 'U R Awesome'.
- Coffee factory, Hosur.
Production Executive
Hindustan Unilever Limited
09.2021 - 08.2022
- Company Overview: Coffee factory, Hosur.
- OR compliance by optimising manpower and resources as per target.
- Manpower & Machine utilization to derive maximum efficiency. Manpower skill assessment and grooming.
- Closely worked with the maintenance team and employees to troubleshoot and took preventive actions to reduce breakdowns, improving quality and upholding safety compliance.
- Planning and implementing predictive / preventive maintenance schedules for machinery to increase machine up-time / equipment reliability.
- Proactively identifying areas of obstruction/breakdowns and taking steps to rectify the equipment's through application of trouble shooting techniques.
- Production booking and Report generation through SAP.
- Identifying nonvalue added activities and eliminating them.
- Continuously improving performance by eliminating waste and losses.
- New Evaporator installation and stabilized in the process plant with OTIF.
- Enhanced employee morale through proactive communication, training, and performance feedback systems.
- Coffee factory, Hosur.
Project Engineer
Hindustan Unilever Limited
08.2020 - 08.2021
- Company Overview: Coffee factory, Hosur.
- Aeration Tank and Digester installation in ETP.
- ESP installation in boiler.
- LPG Plant Installation and commission.
- Implementation of EC blowers in DHU.
- ATFE installation in process plant.
- Liquid Chicory plant installation.
- Building stability.
- Energy efficiency projects.
- RM Extension and New Packing Hall area.
- Thermic Fluid Heater.
- DFT tank, DPHE installation in process plant.
- Coffee factory, Hosur.
Project Engineer
Hindustan Unilever Limited
08.2019 - 07.2020
- SD Drier Tower Expansion.
- Warehouse PEB Structure erection and installation.
- Packing machine installation.
Project Engineer
Hindustan Unilever Limited
03.2017 - 03.2018
- Planning, executing, monitoring & commissioning of gross route projects within stipulated time.
- Handling complete basic engineering and detailing of the projects.
- Preparing cost estimation of the entire project, cost controlling & reduction through proper planning.
- Equipment selection and designing for the projects based on the process requirement.
- Warehouse Engineering management.
- Implemented Condition based Monitoring system for critical equipment.
- Professional maintenance as per WCM way to improve the reliability of equipment's.
- Spares Management system based on ROL & ROQ.
- Have taken care of projects & Maintenance of detergent factory includes equipment's and machineries.
- Worked along with production team on day-to-day improvement and resolving the issue raised by the plant team.
Executive Engineer
Shree Mother Plast India Pvt Ltd
08.2015 - 02.2017
- Responsible for preventive Mechanical breakdown maintenance & production equipment's like Toshiba and Windsor Machine & Ferromatic Millagrame etc.
- Responsible for preventive and break down maintenance of Preform moulds and basket mould and Tub Mould, motors, pumps, Cooling Towers, etc.
- Breakdown and preventive maintenance of LIFT & HOIST.
- Having Knowledge in SAP (System application Programming) for PR raising, Material issue, Service request etc.
Education
MBA - Marketing
Pondicherry University
B.E. - Mechanical Engineering
Achariya College
HSC -
Aditya Vidhyashram
SSLC -
Blue Star English High School
Skills
- Teamwork and collaboration
- Friendly, positive attitude
- Dedicated
- Problem-solving
- Hardworking
- Communication
Father's Name
Karunakaran K
Personal Information
- Passport Number: K-5062488
- Date of Birth: 01/27/94
- Nationality: Indian
Languages
English
Tamil
Hindi
Timeline
Maintenance & Project
Hindustan Unilever Limited
09.2022 - Current
Production Executive
Hindustan Unilever Limited
09.2021 - 08.2022
Project Engineer
Hindustan Unilever Limited
08.2020 - 08.2021
Project Engineer
Hindustan Unilever Limited
08.2019 - 07.2020
Project Engineer
Hindustan Unilever Limited
03.2017 - 03.2018
Executive Engineer
Shree Mother Plast India Pvt Ltd
08.2015 - 02.2017
B.E. - Mechanical Engineering
Achariya College
HSC -
Aditya Vidhyashram
SSLC -
Blue Star English High School
MBA - Marketing
Pondicherry University
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