Devidatta Nayak

• Responsible for whole plant equipment maintenance and utilities . Equipments include - Laser cutting machines (Fiber & CO2) , Press bending machines , Welding machines (TIG welding , Spot welding , Friction welding ,Laser welding etc)Punching machines ,Special purpose CNC machines , VMC machines & Paintshop ( Powder coating & Pre-treatment line). Utilities include - HT line (33 kV), 2 transformers (1600 kVA each), 2300 kVA DG sets, HT and LT panels, 12 air compressors (50 HP, 75 HP, 100 HP capacity), 12 forklifts, and 14 stackers.
• Budget preparation which includes spare parts & services .. Also preparation of CAPEX which includes major investments like upgradation & retrofitment of old machines , investments for cost savings in future , major expensive spares etc .
• Adhere to KPIs like Zero accidents,MTTR , MTBF , UP TIME ,PM compliance, Annual cost saving , Skills enhancement of self and subordinates etc.

• Responsible for plant maintenance and project activities which includes plant expansion projects , maintenance of machines & utilities .
• Responsible for maintenance of Machine shop (laser cutting, bending, CNC machines, welding robots, specially purposed machines), Assembly line (different types of pneumatic equipments/tools), Blade Mfg Plant, Shot blast machine & Paintshop.
• Responsible for maintenance of Utilities (DG set ,Chiller ,HVAC , Air compressor, AHU,STP ,ETP ,Fire Pump& Control , HT & LT Panel, Natural Gas ,LPG yard , Foklifts ,Solar Power Plant etc.

Key Accomplishments:

* Involved in project of plant expansion activities like layout preparation, expansion of electrical distribution system along with instllation & comissioning of new machines as per lean manufacturing principle.

*Handled project of Natural gas conversion of our paint shop, which was previously run with LPG gas for all its burners for oven and degreasing process to reduce CO2 emission and save fuel cost.

*Lead role in project of “ Blade Manufacturing Plant” .( It is a process plant consisting of Furnace , Mechanical Presses

,Quenching Bath Tank along with Shot Blast and Paintshop.)

• Responsible for maintenance of Machine shop, Assembly line & Paintshop.
• Analysis of overall breakdown activities using Pareto analysis, Why - Why analysis, Fishbone, Failure mode effct analysis (FMEA) etc.
• Adherance to KPIs like Zero accidents , UP Time,100% PM compliance , Cost saving , Kaizens implementations etc .

Key Accomplishments:

*Handled a highly critical situation involving recurring Plant equipment breakdown that was aconstant hindrance to production. The current Up-time was 95%

* Conducted detailed breakdown analysis, structured problem solving techniques and deployed knowledge of Pareto analysis to deep dive & analyse the issue, prepared Root Cause Analysis and drafted a detailed action plan

* Achieved the exemplary feat of improving the Machine uptime and scaling it up to >96%

*Tasked to address the rising cost of Repair and Maintenance of the Fabrication shop that was exceeding the budget, driving Spare Part localization strategy and executing Design change for select sub-components that were prone to failure

*Additionally, designed & facilitated Skill improvement program for both operator and maintenance personnel.

*[ Successfully reduced the Lead-time of spare part procurement by 2X, improved reliability of equipment, augmented the Skill level of operators and maintenance crew from 3 against a scale of 5.

*Catapulted prior efforts in Safety improvement through provision of Engineering Interlocks to prevent accidents even without awareness, achieving the remarkable target of Zero accident target and safer workplace.

* Involved in project of new plant set up in Jaipur, Rajasthan and took a lead role for new machine shop line set up for manufacturing of JCB Excavators and Loaders.

*Pioneered practice of periodic assessments & analysis basis objective data studies to significantly impact the Machine Efficiency.

* Involved in JCB Hive concept and set up the practice of retrieving data for actual machine On time and Run time, delivering unprecedented improvement in the matrices.

Key Accomplishments:

*Involved in a major project to set up the PT-CED plant, an attempt to transform the existing paint shop, which was powder coating and involved manual movement.

* Fully automated plant installation was done successfully with advanced technology for painting of load bodies for Tata Motor.

* Played a pivotal role in setting up a new line for the manufacturing of railway wagons and chassis, a role involving the installation and commissioning of a laser cutting machine, a plasma cutting machine, a bending machine, and a robotic welding machine.

Key Accomplishments:

*Involved in project of renewable energy i.e solar power of 1000 Kwp installation

*Harmonic analysis and installation of harmonic filters and control panel to solve electrical faults and unbalanced currents.

*An HVAC system (400 ton) installation for centralized air conditioning inside office space with a water-cooled condenser cooling.

• Maintenance of power transformers and LT panels along with supply of original spare parts .
• Also provide annual maintenance contract of above.