Sachin Kalia

Engineering : Engineering professional with 21+ years of experience across manufacturing environments, spanning plant engineering, maintenance, utilities, asset reliability and operational excellence.

Asset Reliability & Maintenance: Expertise in asset management, preventive/predictive maintenance, RCM, condition monitoring, MTBF/MTTR improvement, breakdown reduction and equipment availability enhancement.

Maintenance Strategy & Optimization: Strong capability in maintenance planning, scheduling, shutdown management, RCA, FMEA, bad-actor elimination and OEE improvement, driving higher reliability and productivity.

Cost & Asset Lifecycle Management: Experienced in maintenance cost optimization, CAPEX/OPEX planning, critical spares management, inventory optimization and asset lifecycle cost control, balancing reliability with business priorities.

Digital

Maintenance & Industry 4.0: Exposure to SAP PM/MM, digital maintenance, predictive analytics, IoT, smart maintenance and data-driven decision-making, leveraging technology to strengthen asset performance.

Projects & Operational Excellence: Experienced in greenfield/brownfield projects, commissioning, PSSR, start-up readiness, MOC, Lean Six Sigma, Kaizen and continuous improvement, supporting productivity and operational excellence. Safety, Compliance & Team Leadership: Strong expertise in machinery safety, LOTO, statutory compliance, ergonomics, EHS, contractor management and stakeholder leadership, with experience developing multidisciplinary engineering teams.

Engineering Manager – Site Operations - Covestro (India) Pvt. Ltd.

(2007)

Formerly Bayer Material Science Pvt. Ltd.

• Site Engineering: Managed engineering and site-level technical operations for a specialty chemicals manufacturing facility, covering maintenance, utilities, infrastructure, engineering modifications, and day-to-day technical support to plant operations.
• Project & Cost Optimization: Executed utility and process modification projects involving pipelines, compressors, chillers, nitrogen generation systems, and pneumatic controls; delivered initiatives with recurring savings and targeted ROI realization within approx. 3–4 years.
• Maintenance Planning: Developed equipment-specific preventive maintenance plans using OEM recommendations, asset criticality, and operating experience; maintained critical spare inventories at approx. 2–3% of equipment value to support reliability and reduce production disruptions.
• Utilities & Resource Efficiency: Upgraded older HVAC systems with VFD/inverter-based equipment and replaced environmentally unfriendly R22-based systems, contributing to approximately 50% reduction in energy/resource consumption across identified initiatives.
• Water Management: Implemented reuse of ETP-treated water through RO treatment for air-washer operations, reducing TDS-related calcium deposition, maintenance frequency, equipment deterioration, and associated manpower/spares requirements.
• Automation & Manpower Optimization: Introduced pneumatic controls and equipment-level automation based on process requirements, reducing manpower requirements in selected operations from 10 to 6 personnel while improving machine safety and operating efficiency.
• Team & Vendor Coordination: Led 6 engineers along with contract technical personnel, providing troubleshooting support, technical guidance, safety training, vendor coordination, and execution oversight for maintenance and engineering activities.

Senior Mechanical Engineer - High Polymer Lab Limited - Faridabad

(2006-01 - 2007-08)

• Managed mechanical maintenance and reliability activities, addressing equipment performance issues and implementing measures to improve operating continuity and asset lifecycle.
• Applied process re-engineering and Lean-based improvement approaches to identify cost-saving opportunities and enhance maintenance and operational efficiency.

Mechanical Engineer – Powerhouse - Daurala Sugar Works - Meerut

(2003-09 - 2005-12)

• Managed mechanical operations and maintenance of the powerhouse, supporting boiler performance, utility availability, equipment reliability, and safe operating practices.
• Monitored equipment conditions and executed preventive and corrective maintenance activities to sustain uninterrupted powerhouse operations and energy reliability.

MBA - Operations Management - Karnataka State Open University

B.Tech - Mechanical Engineering - JRN Rajasthan Vidyapeeth University (2011)

Diploma - Mechanical Engineering - Institute of Mechanical Engineers, Mumbai (2003)