UJJAL TALUKDAR

Dedicated and results-driven engineering professional with over 20 years of experience in automation, plant engineering, and utility maintenance across high-volume solar cell and module manufacturing, aluminum extrusion, and auto ancillary industries. Expertise includes maintenance strategy, plant operations, automation systems, and equipment reliability, all aimed at enhancing operational efficiency and driving organizational growth. Proven track record in leading large-scale maintenance operations, optimizing plant utilities, and implementing preventive and predictive maintenance strategies that improve safety, reduce operational costs, and maximize equipment uptime. Committed to fostering continuous improvement and sustainability while supporting the global transition toward clean and renewable energy solutions through effective leadership of cross-functional teams and complex plant facilities

Operations, Maintenance & Utilities:-

• Responsible for preventive and breakdown maintenance of all electrical and mechanical process machinery to ensure maximum equipment availability and reliability.
• Monitor maintenance expenses and ensure optimum utilization of manpower, materials, and resources.
• Track daily breakdowns and implement preventive and predictive maintenance programs, including planned shutdowns to eliminate recurring failures and improve equipment efficiency.
• Prepare and analyse downtime reports, identify root causes, and implement corrective and preventive actions to minimize equipment downtime.
• Identify opportunities for equipment upgrades and process improvements to enhance operational efficiency and productivity.
• Ensure timely review and updating of preventive maintenance (PM) check sheets and breakdown analysis reports.
• Prepare estimates for critical spares, manpower, and tools required for maintenance activities.
• Maintain all maintenance documentation as per ISO standards, 5S methodology, and statutory compliance requirements.
• Monitor and evaluate energy consumption across different plant areas and implement energy-saving initiatives to reduce operational costs.
• Implement energy conservation measures for process equipment to achieve substantial reductions in O&M expenditure while operating within budget limits.

Equipment & Automation Expertise:-

• Practical maintenance experience of fully automatic German and Japanese-made extrusion presses up to 3300 UST, fully automated handling systems with air and water quenching systems controlled through PLC and SCADA systems. and melting furnaces up to 30 tons capacity.
• Hands-on experience with fully automated solar module manufacturing lines, including: Glass loading machines, EVA cutting machines, Automatic tabber & stringer machines, String layup machines, Auto Bussing machines, Taping machines, Trimming machines, Three-stage laminators, Automatic framing machines, Junction box potting machines, Sun simulator testing machines, Robotic sorting machines.

Automation & Control Systems:-

• Familiar with installation and programming of PLC systems such as:
• Allen-Bradley (SLC 500/3 & 5, ControllLogix, CompactLogix)
• Mitsubishi (FX2N & FX3U series)
• SINUMERIK 840D and FANUC CNC controllers
• Hands-on experience with AC/DC drives from Allen-Bradley, Siemens, Mitsubishi, Schneider, Parker, and Yaskawa.
• Maintain necessary software, manuals, communication cables, and drivers for automation systems.
• Strong knowledge of hydraulic and pneumatic control logic and system operation.

Utilities & Power Systems:-

• Maintenance of plant utilities including:
• Transformers up to 30 MVA
• HT/LT switchgear systems
• PCC, MCC, and APFC panels
• Air compressors up to 500 CFM
• Chillers up to 310 TR, HVAC systems, and air dryers
• Cooling towers
• Gas and diesel engine-based generators (DG sets)
• Experience with HT/LT power systems, switchgear panels, motors, and electrical distribution networks.

Maintenance Planning & Reliability:-

• Maintain equipment history records and maintenance logs for all plant utilities and machinery.
• Maintain records for plant shutdowns, motor failures, overhauling reports, and instrument calibration history.
• Familiar with field instruments such as RTD, pressure transmitters, temperature controllers, PID controllers, and pyrometers.
• Analyses and evaluate MTTR, MTBF, and preventive maintenance effectiveness.
• Develop and manage vendors for maintenance-related materials and services.
• Implement 5S methodology in maintenance stores and inventory management.
• Ensure compliance with government regulations including GEB, GETCO, GAIL, and Electrical Inspectorate requirements.
• Conduct root cause analysis (RCA) and Why-Why analysis to identify equipment failures and implement corrective actions.
• Participate in internal and external audits as per ISO and industry standards.

Project Experience:-

• Managed erection and commissioning activities for various industrial machinery and plant utilities.
• Successfully commissioned:
• Extrusion press up to 3300 UST
• CNC double cutting machines
• 30-ton melting furnaces and quenchable furnaces
• EOT overhead cranes up to 30 tons capacity
• Implemented fault current settings in numerical microprocessor-based relays for 11 kV HT lines.
• Commissioned VCB in HT systems and ACB in LT systems.
• Commissioned Cometal fully automatic aluminum billet heaters and hot log shear systems controlled through PLC and SCADA.
• Commissioned Taiwan-made fully automatic 10-meter, 5-stage handling systems controlled by PLC and SCADA.

Project Management:-

• Prepared capital equipment budgets and project cost estimations with payback analysis.
• Conducted regular inspections to ensure equipment performance, reliability, and operational efficiency.
• Planned and executed plant expansion and machinery commissioning projects to enhance production capacity.
• Developed project schedules, technical drawings, and project documentation, obtaining approval from competent authorities.
• Ensured project completion within scheduled timelines and budget constraints.
• Managed technical and commercial evaluations of switchgear procurement and other critical equipment.
• Monitored manpower and safety compliance during project execution.

Spare Parts & Material Management:-

• Implemented effective procurement schedules with finalized technical specifications, quality standards, and quantity limits for spare parts.
• Coordinated with vendors for timely procurement and inventory management of critical spares.
• Conducted techno-commercial discussions with suppliers to ensure cost-effective procurement.
• Identified alternate vendors and local sourcing options to reduce cost and lead time.
• Prepared annual spare parts budgets for maintenance departments.
• Inspected incoming spare parts and equipment to ensure compliance with technical specifications and quality standards.