SANTHOSH KUMAR BALAJI
Chennai
Summary
Results-driven Maintenance Professional with expertise in enhancing equipment reliability and implementing cost-saving initiatives. Leads teams by fostering a culture of continuous improvement and effective training. Committed to optimising resources and employing best practices to achieve sustainable operational success.
Overview
18
18
years of professional experience
1
1
Certification
Work History
Plant maintenance (HOD)
Endurance Technology Ltd
Chennai - Vallam
12.2025 - 05.2026
- Lead the team of the Professional maintenance management, troubleshooting of Machinery.
- Handling a team of 25 Maintenance personnel.
- Lead and guide team to implement best-in class, proactive equipment maintenance program to enhance equipment reliability and maintainability to reduce downtime and meet pre-set targets.
- Guide team to evolve predictive systems/approach to identify the root cause of the failure and formulate steps for improvement of MTTR & MTBF thereby increasing the availability of equipment’s.
- Conduct RCA for the mechanical breakdowns in the equipment’s and ensure implementation of corrective and preventive maintenance.
- Monitor and Analyses Repair & maintenance cost, Power units.
- Reconditioning of Equipment’s.
- Projects on productivity and cost saving improvement / Kaizens.
- TPM implementation in shopfloor.
- Capex Planning.
- Ensuring on-time PR's and follow up with Purchase.
- Payment schedules & Follow up.
- Preparing monthly Capex reports.
- Monthly Capex meeting & tracking open issues with all responsible personals.
Manager in plant maintenance (Die casting division)
Sundaram Clayton Ltd
Chennai - Padi
01.2017 - 01.2025
- Monitored staff performance and developed improvement plans.
- Managed inventory control, reducing waste and ensuring optimal stock levels at all times.
- Developed and delivered comprehensive training programmes, improving team skills and performance.
- Advised senior management on facilities needs and delivered ongoing operational support.
- Optimised workforce scheduling, balancing team workload to prevent burnout and maintain morale.
- Coordinated strategic plans for administrative services management and optimisation to best use available resources.
- Led team of 25 employees, fostering a collaborative environment to meet project deadlines efficiently.
SERVICE MANAGER
Protos Engineering.Co.Pvt.Ltd.
Chennai
01.2011 - 01.2017
- Organised service department and managed resources to enhance operational efficiency.
- Oversaw daily management of service area, ensuring smooth operations and service delivery.
Maintenance Supervisor
Castwel AutoParts.Pvt.Ltd.
Chennai
01.2010 - 01.2011
- Managed and oversaw daily operations of the maintenance department, prioritising workload for optimal productivity.
- Supervised maintenance team in daily operations, assigning tasks and monitoring performance for optimal productivity.
- Managed planned and reactive maintenance and repairs effectively, limiting operational downtime.
- Responded swiftly to emergency maintenance requests, minimising impact on operations.
- Managed emergency repairs, mobilising teams quickly to address issues and restore functionality.
- Implemented preventative maintenance programmes to minimise downtime and prolong equipment lifespan.
- Analysed breakdowns and failures to identify root causes and prevent recurrence through strategic interventions.
- Investigated complaints related to maintenance services, taking corrective actions to improve satisfaction and quality.
- Collaborated with other departments to coordinate maintenance activities with minimal disruption to operations.
- Managed inventory of maintenance supplies and parts, placing orders to replenish stock as necessary.
- Maintained clean, tidy working areas for optimised staff safety and wellbeing.
- Supervised a team of maintenance technicians, providing guidance and training to enhance skills.
- Maintained smooth-running operations through staff coordination and budget control.
- Participated in budget planning for the maintenance department, justifying needs and optimising resource allocation.
- Kept records of repairs and adjustments to help prevent future issues.
Maintenance Supervisor
Leo Prime Comp.Pvt.Ltd.
Chennai
01.2008 - 01.2010
- Managed and oversaw daily operations of the maintenance department, prioritising workload for optimal productivity.
- Managed planned and reactive maintenance and repairs effectively, limiting operational downtime.
- Supervised a team of maintenance technicians, providing guidance and training to enhance skills.
- Implemented preventative maintenance programmes to minimise downtime and prolong equipment lifespan.
- Coordinated repairs and maintenance work, liaising with external contractors and overseeing quality.
- Analysed breakdowns and failures to identify root causes and prevent recurrence through strategic interventions.
- Investigated complaints related to maintenance services, taking corrective actions to improve satisfaction and quality.
- Monitored facility operations, employee tasks and performance to enforce adherence to safety standards.
- Collaborated with other departments to coordinate maintenance activities with minimal disruption to operations.
- Identified ongoing issues and implemented solutions to maintain optimum service levels.
- Documented all maintenance activities, creating comprehensive records for audit and analysis purposes.
- Developed and maintained records of maintenance activities, including costs, to support budget management.
- Kept records of repairs and adjustments to help prevent future issues.
- Examined work orders to determine priorities.
- Managed inventory of maintenance supplies and parts, placing orders to replenish stock as necessary.
- Supervised and observed team activities, offering praise and constructive feedback.
- Planned incentive programs to maximise employee performance.
- Addressed and solved customer issues and complaints without difficulty.
Education
M.B.A- (Technology Management) - Technology Management
Anna University
06-2026
B.E. (E.E.E.) - E.E.E.
Anna University
Chennai01-2008
P.G.Dip. in VLSI -
Annamalai University
Dip. In E.E.E. - E.E.E.
Directorate of Technical Education
ChennaiSkills
- Preventive Maintenance
- Predictive Maintenance
- Breakdown Troubleshooting
- Equipment maintenance
- PLC/DCS
- HMI
- Drives
- Communication Protocols
- Industrial Robotics
- Process Knowledge
- Project management
- Root cause analysis
- Strategic planning
- Problem-solving
- Team leadership
Certification
Electrical Supervisors “C” License, C57066, 2025-06-29, 2028-06-28
Accomplishments
- Successfully installed higher capacity HPDC machine – Idra 2700 ton in Sundaram Clayton Padi, LK 1600 ton and 2500 ton in Endurance technology Pvt. Ltd and Idra 1300 & 1600 ton in Amzen Machines Pvt. Ltd with complete fully automation.
- Successfully completed training in M/s.Idra (Italy) & M/s.IECI (Italy).
- Successfully completed training in M/s. Buhler (Swiss) & M/s. Fondrex (Germany).
- Successfully installed Medical Equipment Aero comm Gmbh AC3000 Model – Apollo (Chennai), Fortis (Chennai), Apollo (Trichy) and St.John Hospital (Bangalore).
- Successfully Upgrade Medical Equipment Aero Comm Gmbh AC3000 Model with RF- ID Chip-CMC Hospital (Vellore).
- Reduced breakdown hours from 1500 hours to 500 hours to improve operational efficiency, decrease downtime, and save costs.
- Completed Internal Auditing Training Program South Asia TUV/SUD, ISO/TS 16949:2002 Certificated by TUV Management Services (TUV South Asia Private Limited).
- Successfully completed Six sigma – Green belt project (Improve Overall Equipment Efficiency of Machine) in 3200 Tonnage Buhler carat Machine.
- Completed Internal Auditing training program international standard IS 45001:2018 (E) – Occupational Health & Safety Management Systems.
- Improved quality and reduced cycle time from 120 sec to 80 sec by applying Kaizen techniques in production, leading to a 7 % reduction in defects and rework.
- Designed and integrated Poka-Yoke mechanisms to prevent operational mistakes, improving product quality and reducing rework costs which result in quality rejection of product from 15% to 8%.
- We have customized the critical parameters for machine productivity, implemented via Industrial 4.0 revolution.
- Collaborated with cross-functional teams to identify areas where Poka-Yoke could prevent defects, leading to improved customer satisfaction and product consistency.
- Utilized the 4M methodology (Man, Machine, Material, Method) to analyze and identify root causes of quality issues and inefficiencies in production and operations.
- Analyzed the Man (human factors) to identify training gaps or skill deficiencies, implementing corrective actions that resulted in 30% improvement in employee performance and productivity.
- Collaborated in Cross-Functional Teams (CFTs), bringing together expertise from different departments such as development, operations, product management, and customer support to drive successful project outcomes.
- TPM instruction courses – Completed successfully Specially developed for TPM knowledge, organized by JMA consultant Inc.
- Special deployment for US plant – Worked in US plan for 3 months from 2025-02-01 to 2025-05-01 for TPM implementation and Maintenance related stabilization.
Custom
I do hereby declare that the particulars of information and facts stated herein above are true, correct and complete to the best of my knowledge and belief.
Personal Information
- Visa: B1 US visa
- Father's Name: Mr. R. Balaji
Timeline
Plant maintenance (HOD)
Endurance Technology Ltd
12.2025 - 05.2026
Manager in plant maintenance (Die casting division)
Sundaram Clayton Ltd
01.2017 - 01.2025
SERVICE MANAGER
Protos Engineering.Co.Pvt.Ltd.
01.2011 - 01.2017
Maintenance Supervisor
Castwel AutoParts.Pvt.Ltd.
01.2010 - 01.2011
Maintenance Supervisor
Leo Prime Comp.Pvt.Ltd.
01.2008 - 01.2010
M.B.A- (Technology Management) - Technology Management
Anna University
B.E. (E.E.E.) - E.E.E.
Anna University
P.G.Dip. in VLSI -
Annamalai University
Dip. In E.E.E. - E.E.E.
Directorate of Technical Education