SRI VENKATA SAI CH

Core Roles and Responsibilities

• Execute and coordinate all general shift activities, ensuring seamless operational continuity across multiple production lines.
• Monitor real-time equipment performance metrics, and implement immediate corrective actions to maintain optimal efficiency.
• Develop comprehensive maintenance schedules based on equipment availability, production demands, and predictive maintenance indicators.
• Conduct systematic root cause analysis for all equipment breakdowns using structured methodologies, such as the 5 Whys.
• Implement corrective and preventive actions (CAPA) based on failure analysis findings.
• Execute material reservations, purchase requisition (PR) creation, and comprehensive spare parts inventory tracking through the SAP PM module.
• Maintain equipment master data, functional locations, and Bills of Materials (BOM) in the SAP system.
• Generate and monitor maintenance work orders (IW31), ensuring accurate cost tracking and resource allocation.

Additional Responsibilities.

• Ensure adherence to industrial safety standards, OSHA regulations, and company safety protocols during all maintenance activities.
• Conduct safety risk assessments and implement Lock-Out-Tag-Out (LOTO) procedures for equipment maintenance.
• Maintain regulatory compliance documentation, and coordinate with safety inspection authorities.
• Develop and maintain standard operating procedures (SOPs) for equipment maintenance and troubleshooting.
• Create technical drawings, equipment specifications, and maintenance history records for critical assets.
• Prepare comprehensive maintenance reports with KPI analysis, and cost optimization recommendations.
• Implement lean manufacturing principles and 5S methodology to enhance workplace efficiency.
• Lead kaizen events and process improvement initiatives to reduce maintenance costs and increase productivity.
• Coordinate with external maintenance contractors and OEM service providers to ensure quality work delivery.
• Evaluate vendor performance and maintain preferred supplier relationships for critical spare parts procurement.
• Oversee third-party maintenance activities, ensuring compliance with safety and quality standards.
• Mentor junior maintenance technicians in advanced troubleshooting techniques and safety procedures.
• Conduct technical training sessions on new equipment installations and maintenance procedures.
• Collaborate with engineering teams for equipment modifications and upgrade implementations.

• Role and responsibilities
• I taken total substore responsibility with team of 4 members.
• Lead maintenance efforts for hydraulic systems ensuring optimal performance and minimizing downtime.
• Oversee preventive, corrective, and predictive maintenance of hydraulic equipment such as pumps, valves, cylinders, and hydraulic presses.
• Troubleshoot and repair hydraulic system malfunctions, identifying root causes and implementing effective solutions.
• Collaborate with engineering teams to design, upgrade, and optimize hydraulic systems to enhance production efficiency and quality.
• Monitor hydraulic system performance using diagnostic tools, ensuring systems operate within specifications for safety and productivity.
• Train and mentor maintenance staff, providing guidance on troubleshooting, system maintenance, and safety practices.
• Ensure compliance with industry safety standards, conducting risk assessments and promoting safe working practices in all hydraulic operations.
• Maintain accurate maintenance records and generate reports on hydraulic system performance, downtime, and corrective actions.
• Work closely with production teams to align hydraulic systems with manufacturing goals and ensure seamless integration into the overall production process.
• Manage spare parts inventory, cost control measures, and timely procurement of components for efficient maintenance operations.
• Enhanced operational reliability through the development of comprehensive maintenance strategies and procedures.
• Championed energy conservation initiatives resulting in reduced utility costs without compromising facility functionality or productivity levels.
• Conducted regular audits of equipment condition, initiating repairs or replacements as required to maintain optimal asset health.
• Maintained compliance with regulatory standards by ensuring adherence to local, state, and federal guidelines throughout all maintenance operations.
• Coordinated major shutdowns effectively minimizing production interruptions while maximizing equipment availability post-maintenance events.

• Manage all maintenance activities in all shifts with 4 direct subordinates.
• Preventive, predictive and breakdown maintenance activities of Hydraulic systems in Ductile iron pipe mill (CCM, 2000T crushing press, Induction furnaces, Annealing & finishing lines)
• Trouble shooting of all Complex Hydraulic systems & Root cause analysis, Implementation of all counter measures
• Timely condition-based monitoring ( NAS & Vibration monitoring)
• Reduce oil consumption by installing online messaging system
• Reduce breakdown hours from 11h/M to 6h/M.
• Reconditioning, inspection & testing of all hydraulic system assemblies like Pumps, Hydraulic cylinders, Valves (DC, proportional,relief & flow control valves)
• Safety: Ensure safe work practices, Conducting Hazard Identification, Risk Assessment and Control (HIRAC) for all maintenance work stations
• Monitoring SAP works (Breakdowns,PM check list closing..)
• Spares maintenance: Regularly monitoring of spares availability and Rise PR in SAP and follow up material
• Preparing BOM for new equipment in SAP
• Shutdown planning (manpower,materials,etc)
• Posting used materials on sub store in daily basis in SAP.
• Conducted rigorous quality assurance tests, identifying areas of improvement for product optimization.
• Developed work plans for various personnel roles based on strengths and talents.
• Reviewed technical drawings developed by CAD technicians and drafters.
• Read and interpreted blueprints, technical drawings, schematics, and computer-generated reports.
• Prepare and maintain records and documents of ISO audits

• Performed general service for bikes
• Engine repairs and total body disassembling and assembling
• Learn about importance of 5s in work areas