SAJITH T.P.
Experienced Maintenance Expert
Mumbai
Summary
Seeking a challenging Senior Manager Maintenance position within the Plastic manufacturing industry, leveraging extensive experience in injection molding ,Injection stretch blow molding,Injection blow molding &Extrusion blow molding machine maintenance, preventive maintenance program implementation, and team leadership to optimize production uptime and efficiency. Proven ability to manage budgets, reduce downtime, implement cost-saving measures, and ensure adherence to safety regulations while exceeding operational objectives.
Experienced with predictive maintenance techniques to enhance equipment reliability and longevity. Utilizes strategic planning to streamline operations and reduce operational costs. Track record of fostering safety-oriented cultures and adhering to regulatory standards.
Professional maintenance leader with comprehensive expertise in facility management, equipment upkeep, and safety protocols. Proven ability to lead teams effectively, ensuring optimal performance and reliability. Strong skills in preventive maintenance, troubleshooting, and project management. Known for adaptability and results-driven approach, consistently meeting organizational goals and enhancing operational efficiency.
Overview
4
4
Languages
2
2
Certifications
24
24
years of professional experience
Work History
Manager Maintenance
SSF Plastics India Ltd.
05.2025 - Current
- Successfully executed preventive maintenance programs minimizing machine downtime and maximizing production capacity within the packaging industry.
- Reduced operational costs through strategic implementation of water and electricity saving initiatives.
- Spearheaded the installation and commissioning of new machinery and equipment, ensuring seamless integration into existing production lines.
- Successfully maintained a 100% machine uptime record, exceeding production targets, and ensuring on-time delivery schedules.
- Built, trained, and motivated high-performing maintenance teams, fostering a culture of proactive maintenance and continuous improvement.
- Maintained safe working environments by enforcing strict adherence to safety protocols and conducting regular risk assessments.
- Successfully collaborated with cross-functional teams (production, engineering, quality) to optimize overall plant operations and efficiency.
- Successfully managed maintenance budgets, optimized spare parts inventory, and implemented cost-saving techniques to minimize operational expenses.
- Proficient in managing building management systems (BMS) for optimal facility performance and energy efficiency.
- Demonstrated expertise in injection molding machine maintenance, auxiliary equipment management, and ISO quality system adherence.
- Partly looking Hosur unit.
Maintenance Manager
SSF plastics Pvt Ltd.
03.2023 - 09.2024
- Responsible for the overall maintenance operations of the facility, encompassing preventive maintenance planning, scheduling, and execution to maximize equipment uptime and achieve production targets. Managed a team of maintenance technicians, coordinated with government departments for electrical and safety compliance, and implemented cost-saving energy initiatives.
- Developed and implemented comprehensive preventive maintenance plans for injection molding machines, tool room equipment, chillers, cooling towers, and auxiliary systems, resulting in increased equipment uptime and reliability.
- Managed the maintenance of automation equipment for secondary operations, including robots and in-mold labeling (IML) systems, ensuring seamless production processes.
- Oversaw the installation of a new 25-machine injection molding unit, including civil works, electrical and mechanical systems, water and air lines, and utility equipment (chiller, cooling tower, compressor, raw material conveying system).
- Implemented a power monitoring system, water and electricity saving programs, and a rooftop solar system (850 KW) to reduce energy consumption and operational costs.
- Generated and maintained detailed operational and maintenance records for all machinery and equipment, including history cards, mean time to failure (MTTF), and mean time to repair (MTTR) data, to track performance and identify areas for improvement.
- Achievements:
- Achieved 100% machine uptime, exceeding production targets, and ensuring on-time delivery schedules.
- Successfully built and led a high-performing maintenance team, providing training, support, and guidance to enhance their technical skills and promote a culture of excellence.
Manager-Operations
Aspirnova Technoplast
03.2021 - 10.2022
- Responsible for the overall management of plant operations, encompassing production, maintenance, safety, and human resources. Developed and implemented operational strategies, managed budgets, oversaw employee performance and development, and ensured compliance with regulatory requirements. Prepared regular reports for upper management, providing insights into operational performance and areas for improvement.
- Oversaw all aspects of day-to-day plant operations, including production, maintenance, and safety, ensuring a smooth and efficient workflow.
- Developed and implemented strategic plans to achieve growth objectives, optimizing processes for maximum efficiency and productivity.
- Managed operational budgets effectively, identifying and implementing cost optimization strategies without compromising quality or safety standards.
- Oversaw the recruitment and training of new employees, fostering a culture of continuous learning and professional development within the team.
- Evaluated operational and financial performance metrics, identifying areas for improvement, and implementing corrective actions to enhance overall efficiency and profitability.
- Achievements:
- Successfully resolved critical operational issues, such as profit decline, employee conflicts, and loss of business to competitors, demonstrating strong problem-solving and leadership skills.
Manager -Maintenance
Imagination Edutainment India Pvt. Ltd.
02.2013 - 02.2021
- Responsible for the overall maintenance and upkeep of two facilities, ensuring the continuous operation of essential building systems, and providing a safe and comfortable environment for customers and staff. Managed a team of technicians, conducted regular risk assessments, oversaw internal projects and renovations, and managed vendor relationships to ensure optimal facility performance and cost-effectiveness.
- Managed all maintenance activities for two facilities, ensuring optimal functionality and uptime for all equipment and systems.
- Ensured the consistent operation of critical building systems, including HVAC (air handling units, chillers, FCUs), fire safety, electricity, water, PA systems, access control, and building management systems (BMS).
- Conducted regular risk assessments and maintenance committee reviews to proactively identify and mitigate potential issues, ensuring uninterrupted operations and a safe environment for customers and staff.
- Oversaw the execution of internal projects and modifications, including civil works, interior renovations, and MEP (mechanical, electrical, plumbing) fit-outs, to enhance facility functionality and aesthetics.
- Managed vendor relationships, negotiated contracts, and ensured timely and quality delivery of services, optimizing costs and maximizing value for the organization.
- Achievements:
- Successfully maintained minimal downtime for critical equipment, exceeding customer satisfaction targets for facility functionality and comfort.
- Reduced energy and water consumption by implementing cost-effective conservation measures following a thorough analysis of utility bills and consumption patterns.
- Developed and implemented departmental standard operating procedures (SOPs) for facilities management, ensuring consistency, efficiency, and compliance with safety standards.
Manager- Injection Molding
Litaski Electrical Private Ltd
12.2009 - 01.2013
- Responsible for managing all aspects of injection molding operations, including production planning, quality control, material management, and team supervision. Implemented lean manufacturing principles, preventive maintenance programs, and cost optimization strategies to enhance efficiency, reduce downtime, and achieve production targets.
- Planned and managed production schedules, prioritizing marketing requirements and minimizing work-in-progress (WIP), to optimize production flow and ensure on-time delivery.
- Oversaw all aspects of injection molding production operations, including normal and in-mold decoration (IMD) processes, for various plastic components and assemblies.
- Implemented total productive maintenance (TPM), 5S methodology, and history card systems for all machinery and accessories, improving workplace organization, efficiency, and equipment reliability.
- Managed materials effectively, optimizing resource allocation, and minimizing waste to reduce production costs.
- Established and managed a comprehensive maintenance spares inventory, ensuring the availability of critical parts to minimize downtime and support timely repairs.
- Achievements:
- Successfully implemented preventive maintenance plans resulting in a significant reduction in machine breakdowns and enhanced overall equipment effectiveness.
- Developed and trained a skilled team of engineers, technicians, and operators, equipping them with the necessary knowledge and skills to perform their roles effectively.
- Maintained accurate records of operational expenses, tracked actual costs against budget, and implemented cost-saving measures to optimize financial performance.
Asst. Manager - Maintenance
Rosti Technical Plastics
09.2008 - 11.2009
- Assisted the Maintenance Manager in overseeing all aspects of maintenance operations, ensuring the reliability and optimal performance of injection molding machines, auxiliary equipment, and supporting infrastructure. Played a key role in equipment installation, preventive and breakdown maintenance, and spare parts management, contributing to the smooth operation of the production facility.
- Played a key role in the installation and commissioning of new machinery and auxiliary equipment, ensuring they were integrated seamlessly into the existing production line and maintained in optimal working condition.
- Managed the preventive and breakdown maintenance of injection molding machines (IMMs), auxiliary equipment, and molds, ensuring minimal downtime and maximum production output.
- Oversaw the maintenance of server and IT-related equipment, ensuring uninterrupted operation and data integrity.
- Developed and implemented a preventive maintenance plan for hot runner molds and their control systems, extending mold life and enhancing product quality.
- Achievements:
- Maintained accurate and up-to-date records of all machine operations and maintenance activities, contributing to efficient production planning and informed decision-making.
- Optimized spare parts inventory management, monitoring stock levels, and forecasting demand to minimize downtime and reduce costs associated with stockouts or excess inventory.
Maintenance engineerEngineering Head
Mainetti India Private Ltd.
09.2003 - 08.2008
- Supervised all aspects of maintenance engineering to maximize equipment performance and uptime. Led technicians effectively, achieving established production targets. Facilitated establishment of new manufacturing facility, overseeing critical equipment and infrastructure setup. Directed efforts to improve operational effectiveness through strategic infrastructure management.
- Maintained optimal performance and uptime of all production machinery, decreasing downtime and increasing production capacity.
- Created and enforced detailed preventive maintenance plans and schedules for injection molding machines, molds, chillers, cooling towers, and auxiliary equipment, boosting equipment reliability and operational lifespan.
- Administered engineering stores oversight, facilitating inventory procurement and distribution of vital materials and spare parts supporting production and maintenance.
- Integrated new machinery and auxiliary equipment promoting smooth alignment with existing systems and limiting disruption to production processes.
- Created and launched a thorough maintenance and part replacement program founded on operational data analysis, extending working life of machinery and minimizing maintenance costs.
- accomplishments:
- Spearheaded establishment of new state-of-the-art manufacturing facility in Sriperumbudur, overseeing installation of injection molding machines, cooling towers, chiller systems, cooling lines, and fire sprinkler systems, ensuring timely project completion.
- Developed and led high-performing maintenance team, delivering training, guidance, and support to improve technical skills and instill culture of proactive maintenance.
- Identified and rectified mechanical issues to ensure optimal equipment performance.
- Conducted inspections to identify potential hazards and enforce compliance with safety regulations.
- Collaborated with cross-functional teams to streamline maintenance processes and improve service delivery.
- Trained junior engineers on best practices in equipment maintenance and troubleshooting techniques.
- Implemented preventive maintenance schedules to enhance system reliability and reduce downtime.
- Diagnosed and resolved mechanical issues to ensure optimal equipment performance.
- Developed technical documentation for maintenance procedures, enhancing team efficiency and knowledge sharing.
- Led initiatives to upgrade aging systems, resulting in improved operational efficiency and reduced costs.
- Analyzed maintenance data to inform strategic decisions and drive continuous improvement initiatives.
- Reduced downtime through efficient troubleshooting and root cause analysis of equipment failures.
- Reviewed technical documentation to complete equipment maintenance and repair.
- Performed troubleshooting and repair for complex electrical equipment.
- Organized and directed maintenance shutdowns and startups.
- Documented maintenance activities and confirmed compliance with relevant regulations.
- Developed preventive maintenance schedules to minimize downtime and optimize performance.
- Optimized spare parts inventory management for cost reduction and increased availability.
- Enhanced safety standards by conducting regular inspections, identifying hazards, and recommending corrective actions.
- Performed root cause failure analysis on critical equipment, leading to more effective preventative measures.
- Conducted thorough risk assessments before undertaking any maintenance activities to mitigate potential hazards effectively.
Production cum Maintenance Engineer
Litaski Electrical Private Ltd.
03.2002 - 08.2003
- Responsible for both production and maintenance tasks, ensuring the efficient operation of production equipment and the timely delivery of quality products. Monitored production processes, conducted preventive maintenance on machinery, and contributed to the achievement of production targets.
- Monitored and controlled production processes to achieve production targets and maintain product quality, ensuring adherence to established standards.
- Executed all stages of production, from mold loading to continuous production, ensuring the timely delivery of quality products in accordance with production plans (PPC).
- Conducted regular preventive maintenance (PM) tasks on production machinery and molds, ensuring optimal equipment performance and minimizing the risk of breakdowns.
Education
B.Tech. - Mechanical
MGR University
Chennai, India01-2013
Post Diploma - Machine Maintenance
Central Institute of Plastic Engineering & Technology (CIPET)
Chennai, India01-2001
Diploma - Mechanical Engineering
Central Polytechnic
Tharamani, Chennai, India08-1999
Post-Graduate Certificate - Lean Manufacturing Management & Analytics
Indian Institute of Management
Visakhapatnam, India 04.2001 -
Skills
Preventive Maintenance
ISO Quality Systems
BMS
Injection Molding, Injection stretch blow molding ,Extrusion blow molding,Injection blow molding
Preventive Maintenance Planning & Execution
Budget Management & Cost Optimization
Additional Information
ISO 450001:2018 Lead auditor certified.
ISO 50001:2018 Lead auditor certified
Certification
ISO 450001:2018 Lead auditor certified.
Interests
DIY Projects, Automation Tech, Sustainability, Problem Solving, Gadget Enthusiast
Timeline
Manager Maintenance
SSF Plastics India Ltd.
05.2025 - Current
Maintenance Manager
SSF plastics Pvt Ltd.
03.2023 - 09.2024
Manager-Operations
Aspirnova Technoplast
03.2021 - 10.2022
Manager -Maintenance
Imagination Edutainment India Pvt. Ltd.
02.2013 - 02.2021
Manager- Injection Molding
Litaski Electrical Private Ltd
12.2009 - 01.2013
Asst. Manager - Maintenance
Rosti Technical Plastics
09.2008 - 11.2009
Maintenance engineerEngineering Head
Mainetti India Private Ltd.
09.2003 - 08.2008
Production cum Maintenance Engineer
Litaski Electrical Private Ltd.
03.2002 - 08.2003
Post-Graduate Certificate - Lean Manufacturing Management & Analytics
Indian Institute of Management
04.2001 -
Post Diploma - Machine Maintenance
Central Institute of Plastic Engineering & Technology (CIPET)
B.Tech. - Mechanical
MGR University
Diploma - Mechanical Engineering
Central Polytechnic