RAKESH S B
Maintenance Supervisor & EHS Lead
Bangalore
Summary
Results-driven Mechanical Engineer with 15 years of experience in Process and Plant Maintenance Management and EHS compliance. Expertise in optimizing maintenance operations, reducing error rates, and enhancing productivity through strategic CAPEX/OPEX initiatives. Proven ability to lead cross-functional teams in complex manufacturing environments, driving continuous improvement and cost-effective resource utilization.
Overview
1
1
Language
16
16
years of professional experience
Work History
Maintenance Supervisor & EHS Lead
EATON Industrial Products Pvt. Ltd. &
Bangalore
09.2023 - 05.2026
- Overall maintenance & EHS in charge for production process & plant activities
- Lead plant-wide maintenance and EHS operations for aerospace fluid conveyance manufacturing, ensuring high equipment reliability, safety, and regulatory compliance.
- Manage and develop a team of maintenance personnel, driving efficient execution of preventive, predictive, and corrective maintenance strategies.
- Improve equipment performance by reducing downtime and enhancing reliability through structured maintenance planning and root cause analysis.
- Drive compliance with MESH, ISO, and statutory EHS standards, ensuring adherence to safety, health, and environmental regulations.
- Conduct safety audits, risk assessments (HIRA/JSA), and employee training programs, strengthening workplace safety culture and minimizing incidents.
- Oversee maintenance KPIs, scheduling, and workforce allocation, ensuring optimal resource utilization and performance management.
- Continuously improve maintenance processes to enhance operational efficiency, cost control, and asset lifecycle management.
- Lead plant layout planning and modifications, optimizing space utilization, workflow efficiency, and compliance with new projects and maintenance activities.
- Coordinate with external vendors for supplier selection, technical evaluation and procurement (PR/PO processes) for new projects and maintenance activities.
- Act as the primary liaison with government authorities including BESCOM, Fire Department, Electrical Inspectorate, and Factory Inspectorate for audits, certifications, and statutory approvals.
- Collaborate with cross-functional teams and contractors to ensure successful project execution and audit readiness.
- Eaton Industrial Products Pvt. Ltd a MNC located at Devanahalli SEZ park, Bangalore. The plant is equipped to manufacture FED (fluid conveyance products) for aerospace & components parts like hose, couplers, and complex parts for fluid distribution in aerospace domain.
- Job Role Highlights:
- Machines Handled: Production equipment- Pressure testing machines (10000 Psi), auto sleeve cutting machine, drying oven, silicon press machines, Crimping machines ( FP 160), hydraulic hose cut saw machines, Vertical storage machines, Laser marking machines, Videojet printer, Plant equipment: Clean room, Compressor, DG 400 KVA & Material Handling Equipment’s, FA & FP systems.
- Led maintenance initiatives to enhance equipment reliability, minimizing downtime and improving operational efficiency.
- Developed and implemented EHS training programs, fostering a culture of safety and compliance among staff.
- Managed team workflows, ensuring timely completion of maintenance tasks and adherence to quality standards.
- Conducted regular inspections to identify safety hazards, resulting in proactive measures and reduced incident rates.
- Streamlined preventive maintenance schedules, optimizing resource allocation and enhancing equipment performance.
- Mentored junior maintenance staff, promoting skill development and knowledge sharing across the team.
- Collaborated with cross-functional teams to implement process improvements, driving operational excellence and effectiveness.
- Monitored compliance with safety regulations, ensuring a safe working environment and mitigating potential risks.
- Coordinated preventative maintenance schedules, verifying equipment safety and function.
- Facilitated strong communication between maintenance personnel and other departments to ensure seamless coordination during planned outages or emergency situations.
- Established and documented protocols for preventive maintenance procedures, decreasing equipment issues, and reducing downtime.
- Completed partial or full dismantling of equipment to quickly repair or replace defective components and restore functionality.
- Conducted regular performance evaluations of maintenance staff to identify strengths, areas for improvement, and opportunities for growth within the organization.
- Coordinated scheduled shutdowns for major equipment overhauls, minimizing disruption to production schedules while maximizing asset longevity.
- Monitored employee work tasks while installing, aligning, and balancing new equipment for projects.
- Negotiated contracts with vendors for cost-effective materials procurement.
- Analyzed and identified equipment failure root causes and initiated correction actions.
- Mentored junior technicians through hands-on training, fostering a culture of teamwork and knowledge sharing within the maintenance department.
Maintenance Engineer
Denso Kirloskar Industries Pvt. Ltd.
Bangalore
03.2012 - 09.2023
- Process In charge for the Entire heater cores (SFA-II) assembly line in the Company.
- Total 10 SPM’s (Tube making, Fin forming, Tube arranging & core assembly, Sheet metal assembly) Japan make
- After Part Assembly Line and Process Set-up and Monitoring and adherence.
- Coordinate and Manage activities among the Intra-department and Inter-department members (CFT)
- Machine accuracy & condition monitoring & zero breakdown maintenance.
- Defining of measurement standards (Ryohin Joken) & controlling the data through accuracy sheets.
- Person in charge for IATF16949:2016 System Adherence.
- Department documents handling & monthly report making & presenting to top management. Improvement and Monitoring of the Machine OR (Reduction of Losses)
- Change management (5M), Problem Analysis, Why-Why Analysis, FTA, FMEA.
- Work Management through PDCA, Kaizen Management.
- Experience in SPM machines assembly, installation and preventive maintenance Trouble shooting.
- Preparation & Maintaining Process Flow Diagram, Work Instructions, Checklists.
- Knowledge about maintenance management system like MTTR, MTBF, MTTF and MTTA.
- Maintenance & troubleshooting of Hydraulic & Pneumatic Control systems, Hydraulic pump services.
- Planning and effecting preventive, predictive, breakdown maintenance schedules of various machineries and instruments to increase machine up time (MTBF) & equipment reliability & reduce MTTR by work standardization.
- Ensuring all the machineries work efficiently by conducting timely checks, assuring reliability and safe operation of plant equipment’s.
- Conducting Why- Why analysis and take steps to through application of trouble shooting tools.
- Executing cost saving and energy saving techniques.
- Identify and eliminate product and process variation through applications of Professional engineering practices.
- Monitoring and Tuning, Evaluate, define new equipment needs for all process manufacturing with a view to improving product quality and process efficiencies.
- Develop and recommend the forecasted annual capital budget to meet the planned requirements.
- Develop and specify the process parameters for existing and new product introduction
- Defect reduction & machine Operation ratio (OEE) improvement by Breakdown time reduction.
- New machine design reviews by considering problems reflection.
- Work standardization by making manuals & SOP’s.
- Target Setting, Activity Planning & Schedule Management.
- Documentation & presentation to the top management in monthly meetings.
- Goals and Objective reporting to top management & team members.
- Spare Part Management:
- Managing indigenization of the spare parts.
- Monitoring spare parts planning and ensuring cost reduction by doing localization.
- Planning for spare parts needed for annual shutdown or any break down in plants.
- Safety (Work culture) Management:
- Executing safe work culture at workplace by preparing OCP’s, HIRA etc.
- Work safety mind enhance by training to members regarding OGC & IGC incidents.
- Near miss cases prepare & train.
- Led troubleshooting initiatives for machinery, reducing downtime and enhancing operational efficiency.
- Implemented preventive maintenance schedules, ensuring optimal performance of equipment and minimizing failures.
- Collaborated on cross-functional teams to streamline processes, improving maintenance response times significantly.
- Developed training modules for junior engineers, fostering skill enhancement and knowledge transfer within the team.
Engineer-Maintenance
Saint Gobain Gyproc India PVT Ltd.
Bangalore
10.2010 - 08.2011
- Oversaw operations in Board Plant Area, ensuring efficiency and safety standards were met.
- Handling the shift & attending the breakdown.
- Train the sub-ordinates about our group Standards for Safety System (work permit, LOTO, height work etc.)
- Managed spare parts inventory and developed vendor relationships to ensure timely availability of materials.
- Preparing documentation like Maintenance calendar, Shift schedules.
- Exposure to World Class Manufacturing (WCM) Concepts - Autonomous and Preventive maintenance
- Implemented focused improvement initiatives that effectively reduced breakdown incidents.
- Generating OPL, Kaizens for reduction of breakdowns, & assisting other teams by giving mechanical support.
- Participated and won runner up prize in WCM in March 2011.
- Outlined job roles and responsibilities for team members, ensuring clarity in tasks.
- Machines Handled: Hopper, Crusher, Paddle Mixer, Hammer & Ball Mills, Burner, Conveyors (screw, belt, roller), Bucket elevator, Dust collector, Compressor, Pumps, Blowers, Dryers, Hydraulic lifters. Material Handling Equipment.
- Managed various projects and outlined benefits achieved through improvements and innovations.
- Heater core line set up with new technologies & increase in productivity, increase OR up to 88%.
- New age lifter for pallet stacking benefiting to meet the production requirement & part damage control-Cost saving
- Modified return line conveyor system to eliminate 1 man power.
- Waste material management by recycling & reuse by designing conveyor system for work easiness
- Multistage IPA Filtration Unit Setup: Improved operator ease of use and boosted productivity.
- Leak Test Door Modification: Door modification for work easiness & productivity up, Program modification to accommodate the new process requirement.
- STP Area Aeration Improvement: Increased efficiency of wastewater treatment and EHS compliance.
- Civil Projects Refurbishment: Refurbished security rooms and improved infrastructure.
- Leak Testing Machine Guarding Modification: Enhanced operator safety and maintenance productivity.
- Compressed air optimization from 9 bar to 6 bar by installing inline booster resulting in 3.27 lakhs INR & 29T CO2 reduction
Education
Bachelor of Science - Mechanical Engineering
B.T. Lakshman Institute of Technology
Bengaluru, India 04.2001 -
Skills
Maintenance management
Preventive maintenance
Predictive maintenance
Repair strategies
Equipment reliability
Root cause analysis
Asset management
EHS compliance
Accomplishments
- 1. Improving OEE in Fin Forming Machine Situation: Frequent breakdowns and inefficiencies reduced the Operation Ratio (OEE) of Fin Forming & Flux spray machines. Task: Enhance machine reliability and improve productivity. Action: Applied TPM principles, redesigned flux spray system, and implemented preventive maintenance schedules. Result: Boosted OEE from 65% to 85%, significantly reducing downtime and improving throughput.
- 2. Safety & Ergonomics Excellence Situation: Operators faced ergonomic challenges during cutting machine operations, impacting safety and efficiency. Task: Improve workplace safety and reduce operator fatigue. Action: Modified machine guarding, redesigned workstations, and conducted safety training programs. Result: Won the EHS Cup (2025) for ergonomic improvements, while reducing incidents and enhancing operator ease.
- 3. Energy & Sustainability Leadership Situation: High energy consumption and emissions were impacting sustainability goals. Task: Drive energy savings and reduce CO2 emissions. Action: Identified and executed 9 energy saving projects, including fan installation replacing AHU and STP aeration upgrades. Result: Achieved measurable CO2 reduction, recognized as Element Champion in Energy & Air Emission Management (China, 2025).
- 4. Cost Optimization through Spares Localization Situation: High costs and delays due to imported spare parts. Task: Reduce dependency on external vendors and optimize costs. Action: Localized spare parts, developed vendor partnerships, and implemented spares management systems. Result: Reduced costs significantly while ensuring timely availability of critical spares.
- 5. Productivity Boost via Automation Situation: Manual pallet stacking required excessive manpower and slowed production. Task: Improve efficiency and reduce labor dependency. Action: Designed and implemented a new age lifter and automated sleeve cutting/sealing machine. Result: Reduced manpower requirements, improved productivity from 310 to 400 units per shift, and earned the Extra Miler Award
Work Availability
monday
tuesday
wednesday
thursday
friday
saturday
sunday
morning
afternoon
evening
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Timeline
Maintenance Supervisor & EHS Lead
EATON Industrial Products Pvt. Ltd. &
09.2023 - 05.2026
Maintenance Engineer
Denso Kirloskar Industries Pvt. Ltd.
03.2012 - 09.2023
Engineer-Maintenance
Saint Gobain Gyproc India PVT Ltd.
10.2010 - 08.2011
Bachelor of Science - Mechanical Engineering
B.T. Lakshman Institute of Technology
04.2001 -
Languages
English, Kannada, Hindi
Key Results Area
- Leadership & Team Management: Directed multi-disciplinary teams, ensuring alignment of maintenance and EHS goals with organizational objectives.
- Preventive Maintenance Excellence: Formulated and enforced preventive maintenance schedules; maintained critical spares inventory with weekly monitoring to ensure operational readiness.
- Zero Breakdown Strategy: Achieved near-zero machine breakdowns through adoption of PM, TBM, and CBM techniques, driving improvements in machine operation ratio and overall equipment effectiveness (OEE) by eliminating the five major losses.
- Root Cause Problem Solving: Applied TPM methodologies and 7 QC Tools to analyze failures and implement corrective actions, ensuring sustained reliability of critical equipment.
- Continuous Improvement Projects: Contributed to cross-functional team (CFT) initiatives delivering breakthrough improvements in power saving, waste elimination, and workflow optimization. Utilized Why-Why Analysis and FTA for obstruction removal and process enhancement.
- Safety & Compliance: Conducted regular inspections to prevent accidents, enforced safety norms, and strengthened workplace safety culture.
- Lean Manufacturing & MUDA Elimination: Implemented Lean practices to reduce waste, optimize area utilization, and minimize changeover time, supporting Just-in-Time production efficiency.