Shekhar Jotiram Rakshe

• Company Overview: Products: Solvent and water-based decorative paint manufacturing unit, including resin and emulsion processing unit.
• Commissioning (2013-2015) - Commissioned a solvent-based paint processing block, with an integrated pigment handling system.
• Brown Field Expansion (2023-2024) - Water-based paint processing block, and emulsion block.
• Brownfield expansion design and commissioning (2025 - 2026) - solvent-based new product (ongoing) -

Managed aspects of ongoing brownfield projects.

• Capacity calculation: equipment and accessories according to PFD.
• Vendor onboarding: Consultant, Civil, Fabrication team.
• GANN Chart Preparation: Macro and Micro.
• P&ID: P&ID preparation as per engineering standards and freezing.
• Statutory regulations: Drawings review and approval, along with necessary corrections.
• Ordering: The ordering of high-lead items, as per standards.
• Drawings verification: General assembly drawings review and sign-off with final corrections.
• DBR - Design Basis Report Review & Verification.

Managed CAPEX, including design, ordering, and commissioning.

• Brown and blue paint stream capacity expansion.
• SPC reduction - Semi-bulk system
• EHS Capex - Wash Water Reuse Scheme, De-dusting Booth, Hydrant System Above Ground Concept, Hz. Waste TSD design, Hz. Waste management through rack installation.
• Hydrant and sprinkler Capex: unloading bay hydrant/sprinkler system, plant hydrant line above-ground layout.
• Process capex: tanks and associated lines MOC change based on pH value.
• Central Team PIP: Profit Improvement Projects (PARAM, IHO, IHR)
• Process safety management: gas detector, multi-level RTD, flame detector.
• Total lost control: Robot safety study and outcome closure; IR curtains, mech fencing, ABB controller shifting.

Maintenance (Preventive, Predictive, Breakdown, & Shutdown) (2015-2021)

• Team Handling - Prepare the task for the team and ensure adherence: CLRI, daily circulation of records, notifications count, major breakdown count with time, PM pending points, and repair tags.
• MTTR - MTBF - Solving breakdowns with minimum time, maintaining history cards in CMMS for loss and waste analysis.
• Loss and waste analysis – Prepare a report and share it with the team with collaborative, actionable items. (5 WHY, CAPA, Blitz, PIP, etc.)
• Leveraged DCS, SAP, Maintwiz, and MES to monitor MTTR and MTBF, conduct analysis, and perform troubleshooting.
• Refined maintenance frequency using TRACC stages for actionable insights.
• TRACC - Leading and lagging KPI tracking with the help of the data analytics platform (SIGHT MACHINE).

Procurement –

• Preparation of spare list – Critical spare list, creation of its M-code, preparing CCS, ECS, and creating PR/PO, negotiations with vendors.
• Monitored spare part usage and ensured adequate inventory levels.
• Find an alternate solution for imported spare parts – Building up indigenization spares.
• Planned and executed yearly spare parts requirements.
• Managed critical spare parts to prevent operational disruptions.
• Conducted SSR analysis to identify trends.
• Budget preparation for the solvent- and water-based paint processing block – spare, service, and repair.

Safety:

• Implementation of safety standards as per BSC Audit and certification (British Safety Council).
  BBS assessment culture KPI – SUSA, HARP, UA – UC, proactive reporting.
• HAZOP for new processes.
• PSM – Process Safety Management scoring and assessment for the solvent area.
• Ensuring aspect impact study periodically.
  Complete the HIRA for all engineering activities and equipment.
• Prepare the CAPEX commissioning report and sign off from the hierarchy prior to handover to the process team.
• Following LOTO (Lock Out Tag Out) system, permit system, FI-FI, and safety suggestions.
• Maintaining all documents in accordance with APQS and ISO policy. Compliance with statutory inspections for hoists, pressure safety valves, pressure vessels, air vessels, self-cleaning filters, limpet coils, and lifting tackles.
• Ensured compliance with non-statutory inspections for staircases, ladders, and ramps.
• Conducted and maintained comprehensive reports on TBT, TOS, SUSA, HARP UA-UC, and proactive reporting.
• Maintain grievance closure compliance.

• Performed preventive maintenance tasks, including lubrication and cleaning of machines and equipment.
• Routinely inspected plant equipment for signs of wear or malfunctioning parts.
• Maintained accurate records of all maintenance activities performed.
• Diagnosed mechanical problems using visual inspections and test instruments.

• Routinely inspected plant equipment for signs of wear or malfunctioning parts.
• Performed preventive maintenance tasks, including lubrication and cleaning of machines and equipment.