Maintenance and Reliability Lead - PepsiCo - Walker's snack foods - England, United Kingdom
(2024-01 - 2025-05)
Full time role managing Maintenance and Reliability operations.
- Played a vital role in deployment of Augury (£ 500K contract) across walkers' sites, managing an inhouse team of CBM engineers to build and develop predictive maintenance strategies and delivered reliability-driven cost savings of £ 1.2 M+ annually.
- Spearheaded an £800K reliability improvement initiative across two critical Tortilla production lines, reducing unplanned downtime from 6.8% and 7.2% to 2.7% and 3.1%, and achieving a 65% reduction in production losses.
- Delivered annual savings of £1.8 M and improved preventive maintenance compliance from 57% to 95% through optimized maintenance strategies, asset criticality reviews, and CBM enabled maintenance practices.
- Lead a team of reliability and condition monitoring engineers and built several Asset Reliability programs to maximize equipment availability, optimize asset performance, to eliminate repeat failures, reduce unplanned downtime, and optimize maintenance cost and effectiveness.
- Owned the site data analytics systems (PQUIS, Augury, Emmerson CSI 2140 AMS, SPM diamond -Condmaster, E-Maint, SAP, Power BI etc.), and governance while embedding reliability-centered maintenance into long-term site strategy and new asset life-cycle management.
- Managed Condition-based Monitoring and Lubrication programs and implemented preventive maintenance SOP and work orders, which resulted in reduction of reactive hours by 25-30% across site.
- Spearheaded several obsolescence projects from CAPEX proposal, cost benefit analysis, scoping URS, SIPOC, 5 stage spares criticality, technical design, formulating PM strategy, SOP, BOM list, SAP Integration, generating preventive, predictive, corrective maintenance plans, etc.
- Lead the site Asset Reliability Road maps, including MIR/APS/RCA/BDA, FMEA, Criticality Analysis, and RCM/REM governance.
- Governed the effective root cause closure and implementation works to eliminate repeat failures.
- Identify production loss, MTBF, MTTR, cost hotspots, and Top 10 losses to develop and execute action plans.
- Ensure PM systems are value-driven, cost-effective, and aligned with Manufacturing Equipment Excellence and Excellence in Execution.
- Identify and manage asset reliability, obsolescence risks impacting business safety compliance, quality, production, and maintenance costs.
- Partnered with Engineering, CTS, and Planning teams to ensure reliability, maintainability, and LCAM compliance across new and modified assets. Led reliability inputs through project commissioning and startup phases.
- Served as key stakeholder and duty holder for PEMM assessments and value drivers. Ensure compliance within Food Safety, Health & Safety, and ISO 14001 environmental standards.
Senior Reliability Engineer - PepsiCo - Walker's snack foods - England, United Kingdom
(2022-07 - 2023-12)
Full time role focused on establishing CBM presence and developing predictive maintenance programs.
- Established the CBM presence in the company and trained a team of shift engineers and compiled weekly & monthly reports to production and maintenance teams and track reliability progress on Assets.
- Developed and executed preventive and predictive maintenance programs using data analytics and condition monitoring technologies (vibration, thermography, oil analysis, ultrasound etc.), resulted in reducing reactive work by 67% in a year.
- Collaborated with CI & IT teams to deploy 650+ augury IIot sensors and Enable data analytics dashboards that forecast failure trends and improve maintenance scheduling.
- Mentored and coached maintenance technicians and engineers on reliability best practices and problem-solving methodologies.
- Implemented root cause analysis (RCA) processes (5 Whys, Taproot, Fishbone, FMEA) to resolve chronic failures, resulting in a 90% reduction in repeat downtime events.
- Partnered with operations, maintenance, and engineering teams to design and optimize equipment upgrades, ensuring scalable and robust production line performance.
- Championed reliability metrics and KPIs (MTBF, MTTR, failure frequency) to provide real-time visibility and drive continuous improvement decisions.
- Led cross-functional reliability projects (e.g., Ovens Gas efficiency enhancements) that increased throughput while reducing Gas consumptions.
- Driven asset criticality assessments and maintenance prioritization, enabling strategic resources and investment in high-impact areas.
- Ensured compliance with food safety and safety management system standards HACCP, integrating reliability measures with quality and safety objectives.
CBM Engineer - Etex Building Performance - Bristol, England, United Kingdom
(2021-04 - 2022-07)
Full time role establishing CBM presence and building online monitoring systems for critical assets.
- Established the CBM presence in the company and trained a team of shift engineers and Tech-Ops on condition-based lubrication and thermography surveys across site. Built a SPM intellinova online system from scratch on 15 critical assets to indicate early signs of failure while performing periodic calibration checks to ensure data acquisition and flow of data is accurate.
- Compiled monthly reports to production and maintenance teams to track reliability progress on Assets.
- Worked with contractors on specialist reliability projects - Risk assessment's - Signing permits - Providing technical Support to maintenance teams in overhauls, commissioning of equipment and plant shutdowns.
- Building routes and execution of works via OTR findings based on Sampling / Oil analysis from gearboxes, Vibration Analysis on assets, thermal imaging/temp checks and lubrication cycles for plant.
- Worked on lubrication projects with Interflon – lubrication surveys – conversion of existing lubricants on site to Interflon products and proved improvement in reliability via Lubrication cycles.
- Generated 840K / Yr. in cost saving for business during my 1st year of employment. Real time figures based on production hours saved and primarily from early fault diagnosis. Prevented assets from breakdown and supported maintenance teams to do overhauls in a controlled environment as per shutdown.
Technical Sales Engineer - Phoenix traders UK limited - Birmingham, England, United Kingdom
(2019-12 - 2020-06)
Interim role while looking for engineering opportunities.
Condition based monitoring engineer - Hayley 24/7 limited - Sheffield, England, United Kingdom
(2019-01 - 2019-12)
Full time role executing condition monitoring works across UK sites.
- Worked as part of a team and have successfully executed several condition monitoring works in aggregates, quarry, power plants etc. across different sites around the UK.
- Performing remote vibration/stress wave data analysis and asset management using AVT - Machine Sentry, Fluke - Prüftechnik
- Manage the incoming data flow and analyze the data to produce clear, concise, and accurate written reports by combining information from all available CBM technologies to provide the best indication of asset condition.
- Report generation on risk assessment, diagnostics, prognostics, RCM Proposals (Reliability centered maintenance), life cycle of assets, etc.
Configuration Technician - CDW - Rugby, England, United Kingdom
(2018-04 - 2019-01)
Interim role while looking for engineering opportunities.
Maintenance & Reliability Engineer - Axial and Radial Engineering Industries - Coimbatore, Tamil Nadu, India
(2015-01 - 2015-09)
Full time role in heavy fabrication environment managing teams and completing bespoke projects.
- Worked within a heavy fabrication environment, managing a small team of machinists and accomplished several bespoke projects from design to commissioning. Successfully completed several refurbishment jobs dealing with windmills, blowers, Fans, Impellers, pumps, compressors, turbines, gearboxes and mainly Rotating equipment's in most of the government sectors in Southern India.
- Implying root cause analysis to study, understand, implement/eradicate defects and issues.
- Managing teams in commissioning on site and supervising installation of rotating equipment.
- Implying lean process, planning and initiating innovative measures to cut-down costs/time.
Condition Monitoring Engineer - Joy Engineering works - Coimbatore, Tamil Nadu, India
(2013-01 - 2015-01)
Full time role executing condition monitoring and balancing jobs for rotating equipment.
- Worked within a team and accomplished several on-site balancing jobs dealing with rotating equipment like rotors, pumps, impellers, fans, blowers, turbines etc. Executed several condition monitoring specialist jobs at government industries.
- SPIC (Southern Petrochemical Industries Corporation)-Thoothukudi, IND for reconditioning blower, impellers and worn parts of ventilation systems and pumps.
- Glendale tea estate – Conoor, IND for periodic maintenance of tea leaf vibrators and erection of an induction Furnace blower on site.
- SAIL (Steel authority of India) Salem, IND for periodic maintenance, refurbishment of Blowers, ID fans, laser alignment of drive shafts in CRM & HRM plants.
- FACT (The fertilizers and chemical Travancore limited) – Angamaly, IND for condition monitoring and Vibration analysis of a 3-ton woodchipper rotor.
Apprenticeship (Maintenance department) - Dolphin foods dolphin foods ltd - Secunderabad, India
(2012-01 - 2013-01)
Full time apprenticeship in maintenance department.
- Condition Monitoring of FMCG machines and database management.
- RCM service to ensure machine operation is within work environment safety standards.
- Ensuring safe work environment and health standards.
- Data entry and report generation from spreadsheets.
