Balaji K J

E-Mail:kjbalaji25@gmail.com
Mobile: +91-9962532627
PROFILE SUMMARY
 An accomplished with nearly 20+ years of experience in Maintenance Management. Strong knowledge in
Pressshop/BIW maintenance- Transfer press, Blanking press, Mechanical presses, HD presses, Hydraulic presses.
 Robotic Maintenance in KUKA, ABB, Hyundai, Panasonic, Crossbar servo feeders.
 Body Shop experience in manual weld gun, robotic welding, Servo Guns and fixture maintenance.
 Utility maintenance in generator, compressor, cooling towers, EOT Cranes and furnace.
 OPEX Budget, CAPEX Budget cost, inventory management for the entire shop.
 Lead Major maintenance activity every YOY during block closure days.
 Experience in planning & implementing the preventive, predictive & breakdown maintenance.
 Safety of plant equipment & machinery
QUALIFICATION
Bachelor of science (B.S) in Engineering technology (CGPA-6.10) 2008
BITS Pilani, Rajasthan, India.
Diploma in Machine tool maintenance and repairs (SANDWICH, First Class- 76.10%) 2003
C. M. Kothari technological polytechnic college, Chennai.
ORGANIZATIONAL EXPERIENCE (19+ YEAR’S)
Designation Company From Date To Date Exp. Duration
Manager Maintenance GESTAMP PUNE AUTOMOTIVE PVT LTD Aug’ 2023 Till Date < 1 Year +
Senior Engineer FORD INDIA PVT LTD Jun’ 2011 Dec’ 2022 11 Years & 6 Month
Junior Manager SUNDARAM BRAKE LINING LTD Aug’ 2010 Jun’ 2011 > 1 Year
Engineer UNIPRES INDIA PVT LTD Nov’ 2009 Aug’ 2010 > 1 Year
Junior Engineer WHEELS INDIA LTD Jan’ 2006 Nov’ 2009 3 Years & 11 Month
Diploma Trainee KAR MOBILES LTD Dec’ 2003 Dec’ 2005 2 Years

NOTABLE HIGHLIGHTS
 YOY completed 6 sigma GB projects, Eliminated breakdowns & improved quality metrics.
 Reduced breakdowns percentage, Occurrences by identifying the root cause thro Why-Why& 5D Analysis.
 Reduced MTTR and Increased MTBF by achieving in successful implementation of Kaizens.
 Maintained within the budget for all cost elements Fixed cost, Variable cost (NPM, Scrap, power) & Labour
 Cost saving implemented through local procurement, alternate source, direct source, service/ reuse, COE
service/ utilize & external service/ reuse.
 Reduced energy consumption by arresting air leakage& waste elimination across the organization.
 Developed preventive& predictive maintenance activity and successfully implemented.
 Implemented ISO 9001, TS 16949, EMS 14001 & ASES and helped organization to achieve certification.
 Erection and commissioning of new machines, Process lines and proved to perform the process
 Safety–Ensured & comply with all safety, Health and environmental regulations and standards

CORE COMPETENCIES
- Maintenance Management - Predictive / Preventive Maintenance - Project Planning & Management
- Erection & Commissioning - Process Improvement/ Automation - Production Planning & Control
- Lean & Six Sigma Initiatives - Green field projects/ Utilities - Plant Operations Management
- Supply Chain Management - Budgeting/Quotes / RFPs /RFQs - Material Planning / Inventory Control
- Purchase / Vendor Management - Quality & Safety Assurance (HSE) - Regulatory Compliances/ Audits
LEADERSHIP CONTRIBUTIONS
 Y2020 we won Technical excellence award, PHSA & 3rd place in innovation awards (Part of the team)
 Maintenance-in-charge responsible for Maintaining the Plant maintenance & utilities in uptime.
 Coordinator for ISO 9001, TS 16949, EMS 14001 & ASES record, works pertaining for maintenance.
 Final machine inspection carried out in various suppliers end to perform the operation successful.
 Qualified and certified internal auditor for ISO/TS: 16949:2009 quality systems.
 Worked as Resource member for PM pillar activities & SAP PM Module for entire unit.
 Maintaining interpersonal relationship with all team members.
 Executing all major maintenance activities with coordination with suppliers & other stack holders.

AREA OF STRENGTH
 Maintained machines such as Tandem press, Hot Stamping press, Transfer press, KUKA Robots, ABB Robots,
Panasonic Robots, Obara welding guns, Blanking press, Mechanical presses, Hydraulic presses, Screw rod press,
Die spotting press, Furnace, Thermopac Boilers, Generators, Compressors, Cooling Towers, Mig -welding, Butt
welding, Spot welding, Friction welding, SAW welding, Electrical up setter, Servo Spindle, Multi spindle drilling,
Vertical Turret lathe, PLC, Turning lathes, EOT Cranes, Multi axis CNC machine, Scrap conveyors, Fork lifts, Electrical
treatment furnaces, Electrical induction hardening, Grinding m/c, utilities, SPM M/c etc.
 Erection and commissioning of new machines, Process lines and proved to perform the process.
 Cost Trackers established with YOY database to have control over the metrics & achieved within given budget.
 Executed/Lead the major / Block closure maintenance activities.
 Trouble shooting in Hydraulics, pneumatics, and mechanical systems.
 Safety–Ensured that shop facilities comply with all safety, Health and environmental regulations and standards.
 Executing improvements through Kaizens, QC Story & POKE YOKE.
 Productivity improvement projects and online completing for Blanking & stamping.
 Analysis and finding out the real root cause of the problem thro Why-Why, 5D, G8D Analysis.
 Maintaining the list of critical spares required for reducing MTTR by setting MIN-MAX- Reorder level.
 Implement ISO 9001, TS 16949, EMS 14001 –Quality/Environmental Management System.
 Planning& Executing TPM, PM pillar activities and Preventive, predictive maintenance activities.
 Continual Monitoring and Improvement towards achieving the Maintenance objectives.

PROFESSIONAL TRAININGS
 DMAIC Green belt in 6 Sigma.
 MAXIMO For Maintenance (MFM), ONTRACK system for stamping operation.
 Qualified internal auditor for ISO/TS 16949:2009 system.
 Basics of hydraulics, YUKEN INDIA ltd, Bangalore.
 TPM, 8 pillar overview. Planned maintenance.
 Champion user for ERP (SAP) Maintenance module installation.
 ISO 16949:2009, EMS 14001 & ASES Awareness. ISO 9001 (2000 Version).

IT SKILLS
 SAP R/3 System – PM Module, MM Module, HR Module, FO Module.
 MFM (Maximo for maintenance), ONTRACK, P3 Production system, ADP payroll module
 CPRAS, Aurora utilized for spares procurement.
 AutoCAD, MS- Office (Word, Excel & PowerPoint).
 Maintenance records maintained in SQL oracle and FoxPro system.

PERSONAL DETAILS
Date of Birth : 05th May 1985
Marital Status : Married.
Address : F14 AKB Hamlin, Dhargha road, Pallavaram, Chennai – 6000109.