Suresh Kumar S
Kandivali west
Summary
Results-driven Maintenance Manager with expertise in GMP compliance and preventive maintenance. Delivered a 5% reduction in energy usage through enhanced operational performance. Led teams to optimize facility operations, leveraging strong leadership and problem-solving skills. Possesses advanced knowledge in equipment maintenance and repairs.
Overview
4
4
Languages
18
18
years of professional experience
Work History
Maintenance Manager
Abbot Healthcare Pvt Ltd
Mumbai
06.2024 - Current
- Led daily maintenance operations for healthcare facilities, ensuring optimal functionality and safety standards.
- Developed and implemented preventive maintenance schedules.
- Supervised and trained maintenance staff on safety protocols.
- Monitored and enforced compliance with health and safety regulations to maintain a safe working environment.
- Conducted inspections to identify maintenance needs promptly.
- Coordinated with vendors to secure timely procurement of maintenance supplies, supporting uninterrupted facility operations.
- Implemented cGMP protocols at Abbott Healthcare's MDC site.
- Performed predictive, preventive, and breakdown maintenance for GMP and non-GMP equipment including AHUs, dehumidifiers, scrubber blowers, and chillers.
- Ensuring preventive & breakdown maintenance of API manufacturing unit as tablet compression m/blister packaging m/c, granulation, stability chamber, BMS, EMS etc.
- Ensuring periodical and breakdown maintenance for Formulation equipment such as tablet compression m/c, blister packing m/c, blender, lyophilized, vacuum tray dryer, fluid bed processor, co-mill, air-jet mill, rapid mixer granulator, capsule filling m/c, oven, cooling cabinet, deep-freezer, etc.
- Planning & ensuring periodic instrument calibration planner.
- Quarterly submission of statutory compliance wrt DG, Boiler, gas detectors, fire, pressure vessel, lifting tackles, hydraulic test, etc.
- Preparing for internal and regional audits every three months.
- Faced internal and external audits and complied with audit observations.
- Customer & equipment safety Audit and ensure compliance with the engineering data systems.
- Maintenance of lab equipment and production equipment like fermenter, deep freezer, tablet coating machine, tablet filling m/c, compression m/c, vacuum tray dryer, lyophilized, etc.
- Monitored energy usage and implemented conservation strategies to achieve a 5% reduction.
- Planning and allocation of jobs to technicians/ vendors to carry out various jobs in the utility section, service floor, pump house, and any new project-related work.
Manager Maintenance & Projects
Rubicon Research Pvt Ltd
Mumbai
03.2024 - 06.2024
- Handling Maintenance activities for Utilities, Plant equipment for OSD, Electrical Maintenance, Instrumentation, calibration, HVAC Civil, and designing.
- Support the QMS team for Deviation investigation, Change control, and CAPA implementations.
- Handling all Equipment, HVAC, Utility Qualification/Validation, and requalification.
- Followed up on and implemented all safety procedures and systems, and participated in safety audits of utilities, water systems, and HVAC.
- Ensuring compliance with the observations of the safety audits.
- Responsible for statutory compliance of applicable utility systems like; Boiler, Electrical systems, MPCB, NDT Testing of pressure vessels / Earth pits, etc.
- Responsible for the breakdowns, Preventive maintenance as per schedule, and Necessary technical modifications in the equipment of Utility, Packing & process equipment.
- Responsible for Monthly reports related to plant efficiency and breakdown analysis.
- Responsible for Different cGMP audits /Compliance like USFDA.
Technical Maintenance Manager
Abbot Healthcare Pvt Ltd (JLL)
Mumbai
02.2021 - 03.2024
- Managed operations and maintenance at Abbott MDC site, ensuring compliance with CGMP standards.
- Oversaw predictive, preventive, and breakdown maintenance for GMP and non-GMP area equipment.
- Addressed compliance observations from internal and external audits promptly, ensuring adherence to standards.
- Executed periodic validation and qualification planning to enhance operational readiness across all systems.
- Coordinated instrument calibration planning, ensuring accuracy and reliability of all instruments.
- Submitted quarterly statutory compliance reports regarding boilers, gas detectors, and pressure vessels.
- Conducted regular internal and regional audits every three months to ensure quality standards.
- Monitored energy usage trends to identify efficiency opportunities, achieving a 5% reduction in energy use from the previous year.
Manager Maintenance
KCC Paint (India) Pvt Ltd (KCC Corporation)
Chennai
08.2019 - 02.2021
- Valuable experience in greenfield projects (From project setting up to current- Chennai unit).
- Establishing and implementing all Maintenance policies in the plant.
- Developed and implemented a Planned Preventative Maintenance (PPM) schedule, ensuring comprehensive maintenance activities were carried out while leading the team to address missed tasks effectively.
- Taking care of Operation and Maintenance of manufacturing equipment such as Solvent Storage Tanks, Pumps, Twin shaft dispersers, Mixing Vessels, Grinding equipment such as (Basket mill, Double mill, Drais mill), and semi and manual filling machines.
- Taking care of Operation and maintenance of utility equipment such as water-cooled chiller, water-cooled air compressor, air dryer, HVAC, AHU, Air conditioners, cooling towers, diesel generators, Transformers, etc.
- Monitored ambient air quality, ambient noise, and stack emissions in plants to measure pollution levels and initiate preventive actions.
- Tracked daily metrics of groundwater, power, and maintenance unsafe conditions, collaborating with department and plant heads to initiate effective corrective actions.
- Identified environmental losses and implemented strategies for cost saving, energy conservation, and groundwater resource management, leading to reduced losses in safe operations.
- Implemented a safety pre-inspection audit policy for all new machinery, and reworked machinery before starting the operation.
- Effectively delegate any maintenance issues to be resolved on each shift and small project to the right team skills, planning and managing effective works.
- Preparing the monthly reports (MIS) and giving them on time to the senior management (MD-India).
- Preparing & giving department CAPX to the senior management.
- Coordinating all statutory/legal inspections from Govt officials and the plant's HR department.
Assistant Manager - Engineering
Shalimar Paints Ltd (Green Field project - Jindal Group)
Chennai
08.2016 - 07.2019
- As an assistant manager of engineering partnering with production to achieve the budgeted volumes by regulating the plant downtime and supporting process implementation through technology gradations.
- Overall management of repairs and maintenance activities in the plant within budgeted costs to consistently reduce unplanned downtime.
- Supported production teams in enhancing productivity through streamlined processes and improved quality via development of efficient engineering systems and technology upgrades.
- Support the production process through technical inputs on equipment installation, commissioning, and maintenance.
- Established safety protocols that ensured a secure work environment for staff, contributing to compliance and risk mitigation.
- Ensuring all safety systems are in place and reporting and implementing corrective actions on areas.
- Ensuring all statutory requirements concerning plant equipment and machinery.
- Negotiate with vendors and engineering contractors and ensure the best costs for electrical spare purchases & repairs.
- Coordinated team schedules to ensure efficient workflow across departments.
- Find the gaps in maintenance and production and implement the kaizen process to reduce maintenance time.
- Monitoring and controlling MTBF & MTTR for all critical equipment month-wise.
- Implementing 5s and quality management system in & around working area.
- Knowledge of the choice of equipment and electrical apparatus in hazardous / zone areas.
- Developed systems to analyze breakdowns, conducted root cause analyses, and implemented initiatives that effectively reduced unplanned breakdowns.
- Maintaining all documentation with regards to preventive and breakdown maintenance, history card, etc. as per ISO 9001:2015 standards.
- Facilitated weekly maintenance meetings to address issues and coordinate repairs.
- Preparing process equipment replacement plan as per performance base.
- Evaluating / Verifying Yearly budget calculating for spare, service, fuel, and statutory activities.
- Ensuring brown and green field project activities such as Load calculation, panel drawing reading & correction, EB load reduction/addition, equipment design, installation, and commission, etc.
- Managed daily operations for paint production and distribution processes.
Senior Executive Maintenance
Biocon ltd
Bangalore
08.2012 - 08.2016
- AS a Senior Electrical Executive taking care of utility equipment like Water cooled chillers, reciprocating & Screw type air Compressors, nitrogen plants, AHUs, Ventilation systems, A/c, cooling towers, and scrubbers.
- Maintenance of 2000KVA Dry type transformer,50cfm respiratory compressor,300 cfm screw compressor, air handling unit, 360 TR water-cooled chiller, 10 TR air-cooled chiller, Pcc & MCC panels, hot water controls for controlling room humidity, de-humidifier for controlling room humidity, water & oil ring Vacuum pump, cooling tower, pumps etc.
- Taking care of preventive and breakdown maintenance for Formulation equipment such as tablet compression m/c, blister packing m/c, blender, lyophilized, vacuum tray dryer, fluid bed processor, co-mill, air-jet mill, rapid mixer granulator, capsule filling m/c, etc.
- Performed troubleshooting and maintenance on electrical systems to ensure optimal functionality.
- Performed internal and external preventive maintenance for compressors, chillers, MCC, and PCC panels.
- Ensured the periodical Thermography monitoring and acted upon it.
- Monitored energy consumption and implemented conservation activities, achieving a 5% reduction in energy usage compared to the previous year.
- Installed dedicated capacitors on distribution feeders to minimize distribution and current losses, enhancing cable life.
- Led strategic initiatives to enhance operational efficiency across departments.
- Developed and implemented policies to ensure regulatory compliance and quality standards.
Officer - Maintenance
Asian Paints Ltd
Chennai
11.2009 - 05.2012
- Maintenance of Automatic storage and retrieval machine, DG, EOT cranes, Materials handling equipment (MHE), cooling towers, process, and utility equipment, etc.
- Ensuring the periodical internal and external preventive maintenance for Materials handling equipment, DG, Ups, Motors, MCC, PCC, Processing equipment like ASRS, Packing m/c, TSD, transformer, chiller, compressor, mixers, etc.
- Maintenance of automated machines like paint fillers, packing, powder conveying machines, and palletizing robots.
- Monitored MTTR and MTBF of critical machines, implementing strategies that enhanced MTBF and minimized MTTR.
- Closure of Preventive and breakdown maintenance orders in SAP.
- Troubleshooting and maintenance knowledge of Electrical systems.
- Managed vendor relationships to secure timely material supply from key suppliers including Euro fork, SEW, Dematic, Jungheinrich, Sick, Siemens, Schneider Electric.
- Monitored contractor workforce to ensure project timelines and quality standards..
- Developed strategies for sourcing and producing spare parts locally..
- Materials Management through SAP (Material code creation for Imported Materials, Initiation of Purchasing Process, Negotiation, Ensuring Minimum stock of critical spares).
- Preparing Yearly Maintenance calendar for Equipment and uploading the same in SAP.
- Implemented and maintained quality management systems to ensure compliance. & Environment management through ISO 9001, statutory rules follow-up, Preventive maintenance & certification.
- Conducted corrective and preventive action analysis for major breakdowns, identifying root causes and implementing solutions to prevent recurrence.
- Performing RA for all Engineering activities and Reducing RPN by doing modifications.
Service Engineer
Chennai Metco Pvt Ltd
Chennai
08.2008 - 10.2009
- Diagnosed technical issues and implemented solutions, enhancing customer satisfaction.
- Configured and installed equipment, improving performance at client locations.
- Collaborated with cross-functional teams to improve overall service delivery processes.
- Managed inventory of spare parts and tools, ensuring timely service interventions.
Education
B. Tech - Electrical & Electronics
DR M.G.R University
Chennai04-2011
Diploma - Electrical & Electronics
TS Srinivasan Polytechnic And Advance Training Centre
Chennai07-2008
Higher Secondary -
Directorate of Government Examinations
Tamilnadau07-2005
Skills
- Good manufacturing practices (GMP) and compliance audits
- Maintenance management systems
- Preventive and predictive maintenance
- Change control and CAPA management
- SOP preparation and documentation practices
- Internal auditing and risk assessment
- ISO 9001:2015, IATF 16949, ISO 14001:2015
- Statutory compliance and deviation analysis
- Continuous improvement strategies
- Operational performance enhancement
- Cost reduction initiatives
- Training and development programs
- Team leadership and management
- Vendor and project management
- Facility operations and maintenance
- Equipment troubleshooting and maintenance planning
- Energy management systems (BMS, EMS)
- HVAC and electrical systems management
- Installation oversight and safety monitoring
- Building automation systems and data monitoring
- Budgeting, cost control, and financial planning
- Problem solving and resolution skills
- Interpersonal communication and effective communication strategies
Languages
- Hindi
- English
- Tamil
- Kannada
Personal Information
- Total Experience: Over 16 years of experience in engineering maintenance management, focusing on sustainable operations, operational effectiveness, and compliance.
- Title: Head of Engineering Maintenance Manager
- Date of Birth: 07/20/89
- Nationality: Indian
Languages
English
Proficient (C2)
C2
Hindi
Proficient (C2)
C2
Tamil
Native
Native
Kanda
Intermediate (B1)
B1
Accomplishments
- Awards with multiple Abbott Excellence awards for various projects and improvement.
- Awarded with outstanding performer
Timeline
Maintenance Manager
Abbot Healthcare Pvt Ltd
06.2024 - Current
Manager Maintenance & Projects
Rubicon Research Pvt Ltd
03.2024 - 06.2024
Technical Maintenance Manager
Abbot Healthcare Pvt Ltd (JLL)
02.2021 - 03.2024
Manager Maintenance
KCC Paint (India) Pvt Ltd (KCC Corporation)
08.2019 - 02.2021
Assistant Manager - Engineering
Shalimar Paints Ltd (Green Field project - Jindal Group)
08.2016 - 07.2019
Senior Executive Maintenance
Biocon ltd
08.2012 - 08.2016
Officer - Maintenance
Asian Paints Ltd
11.2009 - 05.2012
Service Engineer
Chennai Metco Pvt Ltd
08.2008 - 10.2009
B. Tech - Electrical & Electronics
DR M.G.R University
Diploma - Electrical & Electronics
TS Srinivasan Polytechnic And Advance Training Centre
Higher Secondary -
Directorate of Government Examinations