Sureshkumar K
Trichy
Summary
Achievement-driven professional with 21 years of experience; targeting challenging assignments with an organization of repute Expertise in planning/ execution of Green field projects, commissioning/ operations and maintenance of Tyre Industry Process Equipments like Truck tyre curing press.Radial tyre building machines.Extruder and calendar.Mixers , Fischer cutters .Apexing machine.compressors, Cooling towers, chillers, etc.. Spearheaded the engineering modifications/ Kaizens for process improvements and enhancing productivity Responsible for the Engineering maintenance & PMM concept in Tyre building and Extruders,Calendars.Curing Press Expertise in implementing the Manufacturing Excellence Program in Radial Truck building , Roller head and Steel Calender machines Excellence in planning and effectuating maintenance schedules of equipment and components of plant utilities and process machineries to ensure zero/ minimum breakdown as well as increase machinery uptime and equipment reliability; designed & implementing Preventive Maintenance Program Experience in planning, executing and spearheading Green field & Automation projects involving engineering, resource planning, estimation, site management, client engagement, quality, vendors & subcontractors management Led high performance teams, implemented continuous improvement programs and partnered with multiple stakeholders including clients, vendors and subcontractors for successful completion of projects Rich project management experience with expertise in developing project baselines, monitoring & controlling projects with respect to cost, resource deployment, and quality compliance to ensure satisfactory execution Resourceful in identifying process gaps in the established processes and formulating viable re-engineering solutions to mitigate risks Implementing the new quality systems as a Core team member and Improve the product performance in the field followed by monitoring the critical parameters of the tyre Identify the Bottle neck machines to implement Driving Capacity Growth Program to improve the Machines Capacity Implementing the Cost reduction Program along with M/S Mckinsey from 2017 to 2022 and saved the cost in Various streams
Overview
21
21
years of professional experience
Work History
Senior Manager – Mechanical Engineering (Plant Maintenance & Projects)
MRF Tires
05.2006 - Current
- Administering the entire gamut of maintenance of plant engineering equipments including upgradation/ modernization of equipment and resolution of issues inhouse and with the equipment manufacturers
- Analysing the breakdowns with why why analysis and make PDCA for breakdown reduction
- Implementing PM pillar activities – Identifying Red tag and closures, ensure 100% PM compliance, Monitoring MTTR,MTBF, Breakdown occurrences and downtime, PM effectiveness MTBPM (Mean time between PM) and identifying projects for improvement
- Planning and formulating maintenance plans for machines & equipment
- Implementing plans & schedules for maintenance operations (Preventive, Predictive, CBM, Shutdowns) and annual turnarounds with focus on optimum utilization of manpower & materials
- Monitoring/reviewing of Maintenance schedules periodically for effective running of the equipment, implementation and evaluation of preventive/ predictive maintenance
- Undertaking regular inspections to prevent accidents, adhering to safety norms, work risk assessments, preparing & following SOPs, conducting safety trainings/ engagements, & so on
- Commanding & ensuring all project activities encompassing cost management, change management, resources management, and schedule management are executed in a timely fashion and in accordance with all company standards & contractual requirements
- Monitoring progress of the project on monthly basis reports as per scope, schedule & budgets, and ensured timely completion & delivery
- Attending weekly, monthly and quarterly production & Quality review meetings to understand plant & customers’ queries & requirements and taking actions to address the same
- Effective spares management governing the timely order & inventory function of spares involving planning for storage and use of materials to improve equipment availability and ensure optimum use of components and spares
- Monitoring Repair & Maintenance Budget (Rs/kg) continuously and take stringent cost control measures by optimising spare orders, indigenising of components, identifying cost effective skilled Local service vendors etc
- Planning erection, testing & commissioning as well as preventive & predictive maintenance schedule for the plant
- Reviewing maintenance budgets and take it up with the Management for the final approval
- Responsible for the overall Engineering Safety of the entire plant by strictly ensuring all the mandatory safety releases are strictly adhered
Mechanical Engineer I (Projects & Maintenance)
Hitech Arai Ltd.
05.2004 - 05.2006
Education
Bachelor of Engineering - Mechanical
PSNA college Engineering College
Dindigul, Tamil Nadu01.2004
Skills
- Plant Maintenance
- Trouble shooting
- Problem solving
- Project Planning
- Project Management
- Erection
- Commissioning
- Budgeting
- Cost Control
- Risk Management
- Safety Management
- Quality Management
- Vendor Management
- Contractor Management
- Root Cause Analysis
- PDCA
- Incident Management
- Change Management
Personal Information
Date of Birth: 04/06/83
Languages
- English
- Tamil
Trainings Attended
- Hydraulic maintenance and its troubleshooting
- SAP application and its implementation
- TPM facilitator in MRF Tires
Notable Accomplishments
- Directed the cross-functional team and led engineering/ design/ scheduling and commissioning of electrical equipment/ process equipment; successfully completed the New Tyre Plant Project @ Trichy within the scheduled time
- Pioneered the implementation of engineering modifications and Kaizens for process improvements and productivity; breakdown reduction from 10% to 1%, work away reduction from 10% to 4% and scrap reduction from 5% to 1.5%. Tyre curing scrap reduction from 2.5% to 0.8%
- Pivotal in implementing various Energy Conservation projects with a net savings of more than 8000 units/ day
- Core Team member in implementing the Specific fuel consumption reduction activities. SFC reduced from 90 Litrs/MT to 62 Litre/MT
- Developed master list, maintenance plan, maintenance task lists and scheduling the plan by coordinating with the SAP Consultant for all the process equipments of Tyre industry equipments
- Analysed training needs of the team and developed the team to maintain the equipment in a short span of time
- Active Team member of safety, Suggestion Committee @ MRF LTD
- Leading POKE YOKE projects implementation team and executing more than 50 identified engineering projects for Quality Improvement MRF Plant
- Active member of PM, JH and QM Pillar Team and facilitated the team for Planned maintenance, Process improvement/defect reduction through various Engineering Solutions in MRF Plant
- Member of SHE (Safety Health & Environment) pillar and oversaw overall Engineering Safety. Accomplished HSEE (Health, Safety, Environment and Engineering) certification of all process machineries by strictly implementing Mandatory Safety releases by the management
- Active internal safety Auditor of the Safety Audit Team across the Group plants in MRF LTD
- Accomplished Various Automation projects in the plant enhancing productivity, Safety and Quality of the product
Timeline
Senior Manager – Mechanical Engineering (Plant Maintenance & Projects)
MRF Tires
05.2006 - Current
Mechanical Engineer I (Projects & Maintenance)
Hitech Arai Ltd.
05.2004 - 05.2006
Bachelor of Engineering - Mechanical
PSNA college Engineering College