Sundaramurthy Vijayakumar

• Plan, supervise, and coordinate Process mechanical installation work activities to ensure smooth execution.
• Manage and lead a team of subcontractors to meet project objectives.
• Oversee the installation, alignment, and maintenance of Process Mechanical equipment, including pumps, valves, compressors, and piping systems.
• Review and verify technical drawings, specifications, and blueprints to ensure accuracy during execution.
• Ensure adherence to all safety protocols and MOM regulations on-site.
• Conduct morning safety briefings, toolbox meetings, and risk assessments for all team members.
• Inspect completed work to ensure compliance with industry standards, project specifications, and client requirements.
• Address and resolve any quality-related issues promptly.
• Provide technical guidance, training, and mentorship to team members.
• Evaluate team performance and recommend improvements or additional training as needed.
• Prepare and submit daily progress reports, manpower records, and inspection checklists.
• Communicate effectively with project managers, clients, and stakeholders to provide updates and resolve concerns.
• Follow Installation, Testing commissioning and Maintenance according to System Design.
• Brief Process related activates to contractors and follow closely project scope and ensure system activities to complete on schedule
• Participate in Risk and Process Hazard Analysis
• Promote safe working practices to Sub-contractors
• Responsible for the SHE Performance and safety of sub-contractors and areas under my supervision
• Do review Method of statement for work activity and involve Risk access with Safety team
• Attending daily and weekly progress review meeting
• Follow Documents control, maintaining day to day activity records
• Follow and unsure process installation works as per P&ID and PFD drawings
• Ensuring installations are compliant with approved specification, current shop drawings and current space management drawings
• Follow up all testing and inspection commissioning activities
• Resolving site co-ordination problems with contractors
• Enforcing installation work with quality control in accordance with specifications
• Follow the commissioning activities of all the Process equipment
• Witnessing of testing results for process equipment installation and operation
• Follow installations and commissioning activities of process equipment as per procedures
• Follow up site safety requirements during commissioning, maintenance and operation Like LOTO, proper calibration, permit to work, Risk prediction etc
• Prepare CAPA report, address the root cause of issues, identify corrective and preventive action and closed on-time
• Follow up equipment breakdown and troubleshooting the issue
• Resolve the issue timely and effectively

Maintenance exposure.

• Ability to troubleshoot and resolve complex process mechanical issues efficiently.
• Plan, coordinate, and manage required maintenance tasks with teams and sub-contractors to ensure smooth operations.
• Service and maintain equipment to ensure readiness and minimize downtime.
• Analyse equipment failures, conduct Root Cause Analysis (RCA), and implement corrective actions.
• Atten service preventive maintenance and inspection schedules for both rotating and static equipment.
• Ensure all maintenance activities comply with EHSQ standards and review/implement Method Statements and Risk Assessments (MSRA).
• Responsible for review and check Process related works.
• Conducted thorough site assessments to identify potential hazards, ensuring a safe working environment for all personnel involved in field operations.
• Established rapport with clients by maintaining open lines of communication and addressing concerns promptly and professionally.

Skills:·

• Strong knowledge of Process mechanical systems, equipment, and tools.
• Proficiency in interpreting technical drawings, schematics, and manuals.
• Excellent leadership, communication, and organizational skills.

Projects Handled in Process plant .

Performed Installation, Testing, Commissioning and Maintenance for the bellow projects.

• Waste water treatment plant (WWTP), Local scrubber recycling system (LSR)
• Slurry Dispensing system, Liquid dispensing system.
• Toxic , corrosive, high purity process gas line and equipment installation.
• Concentrated Chemical waste drain collection system.

• Attend daily Preventive (PM) and corrective maintenance (CM) in process equipment
• Follow up PM as per schedule
• Troubleshooting Process equipment issues and implementing corrective, preventive and predictive measures, as required
• During PM, if encounter in any changes in spares, check in OEM manual and submit the request forms with right part no to update in PM task list in SAP
• Prepare Maintenance work instructions
• Support to engineers to prepare Continuously improve the preventative maintenance plans and task lists
• Based on the break down analysis and team member’s observations
• Performed spares registration forms as per OEM manual
• Checked the PM ensure spares availability in as per BOM list in the system (SAP)
• Work together with OEM vendor and external service personal for any Major maintenance activity or troubleshooting
• Ensured the compliance with company and legislative Health and Safety, quality HACCP, safety & cGMP procedures
• Carried out all maintenance activities in compliance with Site Policies and procedures
• Understand SHE requirements
• (like LOTO, permit to Work, Work at height, Hot work, MSDS, Risk assessment, hazardous area classification etc.)
• Having good knowledge and hands-on experiences about Mechanical equipment’s (Exp: maintenance of all types of valves and pumps, agitators, gearbox, blowers, Gaskets, Steam valves and pipe line, bearings and required type Oil & Greasing etc.)
• Predictive maintenance knowledge (Exp: vibration monitoring etc.)
• Having good knowledge about food industry using (wet and dry Process) equipments ( OEM like GEA, Niro, Tetra pak, Nucon, Gericke)
• Having Maintenance experienced in process plant using equipments like different type of valves, pumps and steam valves ( Alfa level, Keystone, Fristam, Spriax sarco, Grundfos , Robuschi , kinetrol
• Gemu,etc)
• Having basic Knowledge in electrical, instrument like VFDs, electrical panels, relays, contactors, Level indicators, temperature transmitters, pressure gauges, silo load cells, flow meters, proximity sensors and read switches
• Preparing newly installed equipment’s maintenance task list and FLOC list, Material list (BOM) for registration purpose in SAP system
• Having experience using SAP in AMM - (Plant maintenance- ERP system)
• Project Experience
• Coordinate and follow up with vendor for installation the new equipment and piping as per P&ID
• Technical drawings and equipment manual
• Support for Installing and commissioning new equipments
• Having supporting project experience in Installation, commissioning of rotating and static equipments like piping, valves, pump and structures
• Involved and Handing Projects:
• 1)ATEX and EKB safety system implementation for Dryer 1,2 and 3
• 2) N2 blanketing in process equipment
• 3) New heater coil replacement projects in spray dryer
• 4) Culinary steam implementation project in Dryer 3
• 5) Explosion vent installation in powder dumping unit
• 6) FAST (Dry blending & Mixing) project
• 7) Equipment maintenance related improvement projects

• Maintain the equipment without down time
• Follow and ensure proper and scheduled maintenance
• Keep spares for planned and shutdown maintenance
• Equipment ownership for assigned tools (chemical gas using semiconductor equipments (CVD tools)
• Follow Equipment preventive and corrective maintenance
• Provided expert technical analysis, and trouble-shooting to resolve equipment down issues
• To follow and support new machines installation and update spares
• Setup equipment in our new manufacturing plant, As per methods and procedures from blueprints, drawings and diagrams
• Performs the set-up, calibration, testing and troubleshooting components, instruments and mechanical assemblies
• Follow up maintenance of dry pump and flow control valve and chillier systems (air and water cooling systems)
• If any major maintenance support with vendor Prepares technical reports summarizing findings and recommending solutions technically to solve the problems
• Assist in the selection and set-up of specialized test equipment and clean room experience

• Follow Maintenance for assigned chemical gas using clean room semiconductor manufacturing equipment, which includes performing, preventive and corrective maintenance
• Support to the Engineers group with testing and experimentation on processes and equipments and collect, document and analyse data from testing
• Monitor, analyse and address SPC issues for the assigned process and respond control issues
• Also participated in retrofit and equipment start up activities to achieve the committed targets
• Troubleshooting and maintenance of Robotic, Pneumatic parts &
• Ultra-high vacuum pumps, gas control MFC
• Responsible for keeping records for the Preventive maintenance & corrective maintenance
• Responsible for keeping records for spares and order spares as per requirements using SAP
• Inspect and measure samples to determine that the equipment’s are operating properly
• To follow and support new M/C setup
• Preparing reports for daily activities and deviations from planning schedule
• Participate work related improvement projects and TPM team
• Experience in semiconductor modules: CVD (200 &300 mm), RTP(300MM), DPN(300MM), PLAD
• Experience in semiconductor machines: Applied Materials, Varian.TEL
• Precision testing & measuring instruments used: KLA-Tencor

• Performed real time line support in carrying out corrective actions for resolving equipment and process problems
• Troubleshooting and maintenance of robotic Assembly machines
• Attend Major OEM vendor support for shut down maintenance for Assembly machines
• To follow and support new M/C setup
• Design & develop test fixtures required for assembly process
• Retrofit and equipment start up to achieve the committed targets
• Inspect and measure samples to determine that the equipment’s are operating properly
• Assisted in planning the daily work schedule within assigned modules to ensure completion of PM and remedial maintenance
• Also ensured that the equipment operate within specifications
• Assisted in developing and implementing plans to increase productivity
• Tracked performance of systems as assigned and assisted in Downtime improvement
• Assisted in Defectively Improvement Program, participated actively and supported improvement projects in the line
• Interfaced between Engineering and Process Control to resolve chronic failures issues
• Utilized Quality Improvement methods and terminology
• Attended program like knowledge sharing with Engineers and maintain all records with in the module as per ISO 9001 Quality System and ISO 14000
• Follow up 5S activities

• Company Overview: (Worked for MAN TAKRAF FORDERTECHNIC GMBH, Germany)
• Erection and troubleshooting, carryout maintenance of Fertilizers / Thermal power plant / Heavy Mining Machineries (Bucket wheel excavator, spreader)
• Follow up erection machine parts as per Technical drawings
• Attend modification works to achieved committed targets
• Performing maintenance in different types of pumps
• Read technical specifications and assembled Services parts as per drawings
• Erection of both static and rotating equipment
• Alignment of Pump and Knowledge of Welding and Gas cutting

• Operating and programming of CNC machining centre
• Follow up production target as per schedule
• Follow up daily maintenance
• Attend minor break downs and assist to service vendor when doing major breakdowns of CNC machines
• Keeping records for productivity and m/c maintenance

• Performs routine mechanical, welding and machining maintenance activities on equipment including lubrication, inspection, and replacement parts
• Order and maintain stock levels of lubricants used in plant equipment
• Conducts performance tests of plant equipment using tachometers, pressure gauges etc.
• Diagnoses, troubleshoots, updates and repairs malfunctioning plant equipment; maintain, repairs and overhauls treatment plant equipment, pneumatic equipment and hydraulic pressure systems
• Performs pipefitting, install and repair air, sewer and hydraulic piping systems
• Maintains efficient records on operations and activities
• Maintains plant safety records for plant function readings and equipment history maintains preventative maintenance records and schedules
• Lockout/tag out and safety regulations