Santosh Singh

Strategic Mechanical Maintenance & Reliability professional with expertise in alumina refinery operations, driving equipment reliability, operational continuity, and maintenance excellence across critical process areas including PDS, Digestion, Ball Mill, and Evaporation units. Proven capability in leading Preventive, Predictive, Corrective & Breakdown Maintenance programs for rotating and static equipment such as centrifugal pumps, slurry pumps, agitators, gearboxes, valves, heat exchangers, and EOT cranes, ensuring maximum plant availability and reduced equipment downtime. Strong experience in Shutdown & Turnaround Management, including maintenance planning, manpower deployment, spare coordination, risk assessment, and execution of high-impact maintenance activities within strict safety and operational timelines.

Demonstrated expertise in Reliability Engineering and Failure Analysis, with a strong focus on MTTR reduction, MTBF improvement, Root Cause Analysis (RCA), Condition Monitoring, and implementation of sustainable corrective actions for recurring equipment failures. Effective leader in managing cross-functional teams, contractor workforce, and interdepartmental coordination, ensuring seamless execution of maintenance operations while maintaining compliance with safety, quality, and operational standards. Safety-driven maintenance professional with in-depth knowledge of LOTOTO, Work Permit Systems, Hazard Identification, PPE Compliance, and safe work practices, consistently promoting a proactive safety culture and operational discipline across plant maintenance activities.

Assistant Manager – Mechanical Maintenance at Vedanta Lanjigarh (2023-03 – Present)

Responsible for maintenance and reliability of rotating and static equipment in alumina refinery operations. Leading preventive and breakdown maintenance activities while ensuring safety compliance and uninterrupted plant operations.

• Spearhead Preventive, Predictive, Corrective, and Breakdown Maintenance activities for critical rotating and static equipment to ensure maximum plant reliability and operational continuity.
• Lead and execute shutdown and turnaround maintenance activities, including planning, scheduling, manpower deployment, spare management, risk assessment, and timely job completion within targeted timelines.
• Drive equipment reliability improvement initiatives through effective troubleshooting, Root Cause Analysis (RCA), failure investigation, and implementation of sustainable corrective actions.
• Manage maintenance activities for centrifugal pumps, slurry pumps, agitators, gearboxes, valves, heat exchangers, and EOT cranes, ensuring optimum equipment performance and reduced downtime.
• Monitor equipment health through condition monitoring techniques and reliability-focused maintenance strategies aimed at improving MTBF and reducing MTTR.
• Coordinate seamlessly with Operations, Planning, Workshop, and Safety teams for efficient execution of maintenance jobs and uninterrupted plant operations.
• Supervise departmental and contractor manpower, ensuring adherence to maintenance standards, productivity targets, and safe work execution.
• Ensure strict compliance with LOTOTO, Work Permit Systems, Hazard Identification, PPE compliance, and refinery safety protocols to maintain a zero-harm work environment.
• Conduct toolbox talks, safety briefings, and on-site hazard assessments to promote a proactive safety culture across maintenance teams.
• Maintain and update critical maintenance documentation including equipment history records, inspection reports, maintenance logs, shutdown reports, and compliance documentation.
• Support maintenance planning and inventory optimization by coordinating spare part requirements, resource allocation, and emergency maintenance preparedness.
• Contribute to continuous improvement initiatives focused on enhancing equipment availability, maintenance efficiency, operational reliability, and cost optimization.

Bachelor of Technology (B.Tech) in Mechanical Engineering – Indira Gandhi Institute of Technology (IGIT), Dhenkanal (2022)