Plant Maintenance & Reliability Manager - Ganesh Febric Industries - Surat, Gujarat, India
(2024-01)
Direct all maintenance and reliability operations for a capital-intensive 200+ machine heavy industrial plant, covering mechanical, electrical, hydraulic, and pneumatic systems.
- Designed and deployed a Reliability-Centered Maintenance (RCM) framework; achieved 12% reduction in unplanned downtime within 6 months and zero production stoppages during peak output periods.
- Diagnosed and resolved complex hydraulic, pneumatic, and mechanical failures on heavy-duty industrial equipment including compressors, conveyors, presses, and CNC-integrated machinery.
- Built and managed a CMMS-based work order system tracking 500+ preventive maintenance tasks per month; improved first-time fix rate and mean time between failures (MTBF).
- Negotiated vendor contracts and optimized spare parts inventory, reducing procurement costs by 15% while maintaining 99%+ parts availability for critical assets.
- Led and mentored a team of 10+ maintenance engineers and technicians; structured a skills matrix and cross-training program to enhance team flexibility and reduce single-point dependency.
- Managed full ISO/OSHA safety compliance across the plant; conducted weekly safety audits with zero recordable incidents in the past 12 months.
Loss Prevention / Operations Executive - Flipkart India Pvt. Ltd. - Surat, Gujarat, India
(2026-02 - 2026-06)
- Conducted seller and hub visits for on-ground verification and audits.
- Performed hub audits to ensure process adherence.
- Identified process breaches, fraud risks, and operational loopholes.
- Supported investigations and vigilance activities.
- Prepared audit reports with clear findings and recommendations.
- Monitored CCTV camera networks, high-value storage areas, and movement of goods within the facility/hub.
- Investigated instances of internal theft, missing shipments, fake/damaged CX returns, and system discrepancies.
- Collaborated with cross-functional hub operations teams to build risk mitigation strategies.
Mechanical Production Line Engineer - Ganesh Febric Industries - Surat, Gujarat, India
(2021-01 - 2023-12)
Managed and continuously optimized high-volume industrial production lines executing 500+ daily production cycles, sustaining OEE above target thresholds.
- Applied Lean Manufacturing and Total Productive Maintenance (TPM) principles; delivered a 7% productivity increase across all production lines through loss elimination and process standardization.
- Reduced scheduled maintenance backlog by 30% through priority-based work planning and resource optimization, directly improving equipment availability.
- Coordinated cross-functional improvement projects with quality, production, and engineering teams to reduce defect rates and improve first-pass yield.
- Oversaw preventive maintenance schedules for rotating equipment including pumps, motors, gearboxes, compressors, and conveyors; reduced emergency repair costs significantly.
Mechanical Production Engineer - Ganesh Febric Industries - Surat, Gujarat, India
(2019-01 - 2020-12)
Managed day-to-day industrial production operations ensuring optimal equipment efficiency, throughput consistency, and product quality compliance.
- Led a team of 15 technicians and operators with strict adherence to safety protocols and production KPIs; zero lost-time incidents during tenure.
- Implemented Lean and Kaizen techniques across the production floor, reducing material waste by measurable margins and improving overall process flow.
- Coordinated with procurement and supply chain teams to ensure timely availability of raw materials and critical spare parts, eliminating supply-related stoppages.
- Analyzed production reports and OEE data to identify bottlenecks; implemented corrective actions that drove sustained throughput improvement.
Mechanical Maintenance Engineer - Ganesh Febric Industries - Surat, Gujarat, India
(2018-06 - 2018-12)
Performed preventive and corrective maintenance on heavy industrial equipment including loom machines, spinning frames, dyeing vats, and finishing equipment.
- Diagnosed and resolved mechanical failures using structured Root Cause Analysis (RCA) methodology to eliminate repeat failures and reduce MTTR.
- Implemented energy optimization strategies that reduced consumption on compressed air and HVAC systems, contributing to plant-wide energy efficiency goals.
- Supervised and trained junior maintenance staff on safety protocols, maintenance best practices, and CMMS record-keeping.
Junior / Trainee Mechanical Engineer - Ganesh Febric Industries - Surat, Gujarat, India
(2018-03 - 2018-05)
Assisted in machinery installation, commissioning, overhauls, and routine inspections of industrial equipment under senior engineer supervision.
- Maintained CMMS maintenance records and coordinated with vendors for spare parts procurement, ensuring timely availability for scheduled jobs.
- Supported development and rollout of initial predictive maintenance schedules for rotating equipment.
