DEEPAK KUMAR
Mobile: +7 702 962 5333 / +91-99716-35212 ~ E-Mail: deepak_11171@yahoo.co.in
MANAGER MAINTENANCE
Industry Preference: Mining and Metals/ Construction industry Location Preference: Asian and African Countries
PROFILE SUMMARY
• Maintenance Management Professional with 22 years of experience in Mining and Metal industries
• Develop and implement business processes in a start-up operation for large scale Green Filed Mining operations, managing project activities, resource planning and execution to facilitate smooth start- up of maintenance operation.
• Demonstrated Safety focus for promoting safety as a culture in the team – Achieved 1400 days LTI free while managing a team of 250 plus maintenance workforce.
• Able to effectively establish and implement CMMS for asset management, Actively managed two end-to-end implementation of SAP-PM and Oracle eAM for enhancing maintenance management
• Demonstrated ability to drive changes and deliver results, manage conflicting priorities and leadership abilities in motivating and guiding multidisciplinary maintenance teams.
• Proactive professional with excellent relationship management, teamwork and leadership skills along with an ability to establish effective partnerships with suppliers and customers.
EMPLOYMENT DETAILS
• Responsible for the efficient Asset Management of the Heavy Mining equipment fleet and Mine site support equipments fleet by approaching maintenance as a continuous improvement process with the goal of safety, enhancing asset reliability and optimizing costs.
• Develop and Implement Life cycle maintenance strategies through continuous improvement process including maintenance work execution efficiencies, root cause failure analysis and Reliability Improvement programs
• Implement modern maintenance approach for Predictive and Proactive maintenance – online management of Asset health through Telemetry Monitoring.
• Lead, demonstrate and educate maintenance team to enhance maintenance and repair capability within the maintenance department. Mentor and develop National staff to achieve high levels of skills through Succession Planning. Currently managing a team 4 expats and 256 Nationals in Kazakhstan.
• Forecast and Manage Maintenance Budget - CAPEX, OPEX and LIFE OF MINE, Manage contractors to ensure safe, compliant and timely deliveries.
• Monitoring and reviewing maintenance KPIs and practices for continuous improvements, incorporate modern maintenance system & procedure to remain competitive.
• Ensure HSE and quality standards are incorporated in maintenance system & procedure, train people on safety best practices and ensure safety culture is embedded in the team.
• Resource Management, Ensure maintenance team is timely provided with all necessary resources (Budget, Manpower, spare parts, right tools) to efficiently implement maintenance plan and enable Operation achieve production targets.
• Performance Management And Reporting, Set clear guidelines and expectation for teams performance, monitor KPIs reports which identify trends in maintenance activities and suggest improvement as per trend to improve safety, efficiency and cost effectiveness
• Communicate effectively with all stake holders (Operations, SCM, Finance and OEM dealers) to resolve issues and bottlenecks, Provide strategic input to the Management team on the latest development and potential opportunities to align with the company vision of a world class mining operation in Kazakhstan.
• Develop Maintenance strategy, SOPs, organizational design, and establish work standards for the startup operation of the Green field projects.
• Recruit and build a team of qualified and experienced national workforce for the start-up operation
• Create Maintenance contracts, OEM service agreements to ensure the presence of OEM service technician on site so that the national workforce which were recruited from various different background are trained on equipment maintenance and standard maintenance practices are not compromised.
• Facilitate and manage forecasting activities for Spare parts, identify and plan first fill spares, equipments and tools needed for start-up operation and ensure availability of all critical spare parts to avoid downtime due to waiting for parts.
• Design and implement computerized maintenance management system (CMMS - Oracle eAM)
• Budget Formulation, Implementation and Control, Prepare annual maintenance budget incorporating life cycle cost of equipment.
• Set-up and drive efficient maintenance Strategy for the Mobile equipment fleet and Fixed plant while aiming safety, controlling costs and increasing reliability
• Prepare monitor and control maintenance budget for Mobile and Fixed plants. Manage major Shutdowns and improve the shutdown times
• Responsible for forecasting activities for components & parts for maintenance activities and ensuring availability of all critical spare parts to avoid downtime
• Ensure maintenance contracts, OEM service agreements and coordinating with OEM dealers on issue related to maintenance, failures and warranty claims
• Oversee workshop safety and compliance towards company policies & procedures.
• Lead the implementation of standard data management system to generate the reliable data at source and ensure all maintenance data are captured & reported through Oracle eAM
• Generating relevant KPI reports which identify trends in maintenance activities and recommending improvements as per trend to improve efficiency & cost effectiveness
• Managed a team of 12 Planner, Scheduler and Plant Engineers
• Planned preventive and predictive maintenance for a fleet of more than 150 heavy earth moving equipment of various OEMs (CAT, HITACHI, KOMATSU, LIEBHERR, O&K and P&H)
• Facilitated Component Replacement planning based on life & health of equipment for the fleet to reduce downtime & cost of maintenance, failure analysis and warranty management.
• Responsible for maintenance Work order & notification management in an ERP environment (JD Edwards)
• Trained team members and fixed the responsibilities through 3W action plan to ensure enhanced results
• Manage KPI reports from JDE database- availability, maintenance cost, asset utilization, MTBS and MTTR
The Growth Path
Jul’97 - Jun’99 Asst. Maintenance Engineer Jul’99 - Dec’01 Supply Executive
Jan’02 - Mar’04 Maintenance Engineer Apr’04 - Mar’06 Sr. Maintenance Engineer
As Sr. Maintenance Engineer
• Efficiently managed a team of Maintenance Engineers and Supervisors for maintaining a fleet of eighty heavy earth moving equipment (CAT, Hitachi & Komatsu) and ensured fleet availability to meet the production target as per plan, Manage shutdown for Major overhauls of mining equipments
• Worked as TPM Pillar Head for planned maintenance & support of Jishu Hozen as part of TPM implementation program.
• Equipment performance (availability, utilization, MTBF, MTTR, maintenance cost) using an approach to maintenance incorporating principles of TPM and the Kaizen philosophy, and then create plans, programs & strategies for personnel and equipment improvement
• Ensure compliance to Safety, Quality & Environment Management system (ISO 9001 and ISO 14001)
• Implementation of ERP-SAP and work as a power user for system enhancement and impart training to the end users
As Maintenance Engineer
• Managed a a fleet of both, overburden & raw coal removal heavy earth moving machineries i.e. 40 no. dump truck of Caterpillar & BEML, 10 No. coal haulers of HM-1160, 06 loaders of HM- 2071 and three water sprinklers
• Responsible for maintenance, repair, troubleshooting of mining equipment fleet
• Worked towards implementation of Total Productive Maintenance on Earth Moving Equipment
• Provided training to Operators to enhance their knowledge on equipment
As Supply Executive
• Ensured timely availability of spares to meet the planned maintenance requirements for a fleet of 100 equipment (dump trucks, excavators, dozers, coal haulers, pay loaders, water sprinklers) having different makes & models
• Sigle Point of Contact between Maintenance and Procurement Department, Coordinate with Maintenance Engineers for their spare parts requirements. Improve availability of spare parts to reduce downtime.
• Accountable for standardization of spare-parts across the fleet of equipment
ACHIEVEMENTS
• Part of implementation team for cost reduction project “Total Operational Performance” launched with the help of McKinsey Co. in different areas of maintenance and operation with a saving of USD 1 Million at TATA STEEL West Bokaro Mine site.
• Improved OTR Tyre Management process and reduced OTR tyre cost and downtime in Heavy Earth Moving Equipments and achieved a saving of USD 250,000.
• 8% reduction in overall operating cost at Mawarid Mining Oman by improving mobile equipment reliability and reducing maintenance re-work.
• 10% improvement in availability of Haul Trucks at Mawarid Mining Oman by downtime analysis and resource management process.
• Successful implementation of ERP –Oracle for asset management at KAZ Minerals and Mawarid Mining, worked as a Project Manager SAP at TATA STEEL
WORKSHOPS / CERTIFICATIONS
• ISO 9001 – Certification
• ISO 14001 – Certification (Environment Management)
• Certified TPM Instructor by TPM club of India
• Total Productive Maintenance
• RCM – Reliability Centered Maintenance
• Six Sigma
• Junior Management Development Program
EQUIPMENT MANAGED
• CATERPILLAR – Haul truck CAT 793D, 785C/D, 777D, 773E : Dozer D11T, D10T , D9R : Grader 16M, 16H : Loader 994k, 993K, 988H, 980H : RTD 844K, 834K
• KOMATSU – Excavator PC1800 , 1250 : Haul Truck 530M, HD 785 : Dozer D375-5
• LIEBHERR – Excavator R994, 995 : O&K RH170
• HITACHI – Excavator EX5600 , EX3600, EX2500, and EX1200: ZX870, ZW330
• SANDVIK – Drill DI600 , D55 SP
• METSO – Mobile crusher LT116, LT300 GPB : TEREX – Cranes
BUDGET AND TEAM SIZE
• Managed a team of up to 250 members of national and expatriate employee in KAZ Minerals Kazakhstan.
• Financial management accountability includes 34 Million USD OPEX and CAPEX budgets in KAZ Minerals Kazakhstan for a fleet Size of 300+ mobile equipments
ACADEMIC DETAILS
• B.Sc. Engineering (Mechanical) from National Institute of Technology (NIT), Jamshedpur, India in 1996 passed 1st class with distinction
IT SKILLS
• Conversant with Microsoft Office (Excel & PowerPoint) and MS Project
• Expertise in CMMS implementation SAP and Oracle
PERSONAL DETAILS
• Date of Birth: 1st November, 1971
• Nationality /Passport Origin : Indian
• Languages Known: English, Hindi, Russian-basics, Bahasa Indonesian and Arabic-basics