MD AKRAM ALI

• Improved team productivity with regular communication and progress updates, fostering a collaborative work environment.
• Entered data, generated reports, and produced tracking documents.
• · Maintenance Planning & Scheduling: Develop and implement preventive, predictive, and reliability-cantered maintenance (RCM) strategies using SAP PM, CMMS, and Primavera P6 to enhance asset performance and reduce downtime.
• · Asset Performance Management (APM): Monitor and analyze Key Performance Indicators (KPIs) such as Mean Time Between Failures (MTBF), Mean Time to Repair (MTTR), and Overall Equipment Effectiveness (OEE) to optimize system reliability.
• · Shutdown & Turnaround Planning: Plan and execute scheduled maintenance, shutdowns, and turnarounds for HV/LV switchgear, transformers, motors, and MCC panels, ensuring minimal operational disruption.
• · Work Order & Permit Management: Oversee the work order system in SAP PM, ensuring compliance with LOTO (Lockout/Tagout) procedures, work permits, and HSE requirements for safe execution of maintenance tasks.
• · Condition Monitoring & Diagnostics: Implement condition-based monitoring using thermography, vibration analysis, partial discharge testing, and oil analysis to predict failures and enhance asset reliability.
• · Spare Parts & Inventory Control: Manage spare parts procurement and stock levels using SAP MM (Materials Management), ensuring cost-effective inventory control while preventing shortages of critical components.
• Collaborated with department heads to develop strategic plans aligning with overall company objectives, fostering a unified approach toward shared goals.
• · Risk & Failure Analysis: Conduct Root Cause Analysis (RCA), Failure Mode and Effects Analysis (FMEA), and Reliability-Centered Maintenance (RCM) to improve system reliability and reduce unplanned failures.
• · SCADA, PLC & BMS Coordination: Work closely with automation teams to integrate SCADA, PLC (Siemens, Allen-Bradley), and BMS systems for predictive maintenance insights and operational efficiency.

• Supervised technicians and assigned responsibilities.
• Supervised employee performance, preventive maintenance, and safety.
• Completed preventive maintenance to maintain production and equipment following safety protocols and company policy.
• Established and documented protocols for preventive maintenance procedures, decreasing equipment issues, and reducing downtime.
• Increased equipment reliability by proactively identifying potential issues and implementing appropriate corrective actions.
• Developed standard operating procedures for routine maintenance tasks, providing clear guidance to team members and improving overall consistency in work execution.
• · Maintenance of HV 11KV substation, 11KV/420V transformer, LV switchgear, harmonics filter, and PF correction panel.
• · Managing PLC modules (analog, digital I\O modules) connection wiring online operations, status, power supply also SCADA program troubleshooting, checking with ladder logics.
• · Maintain motor control starter MCC like DOL, Y - ∆ starter, motor drives (Rockwell) MCC and soft starters, LV panel, SMDB, and DB, ELV panels, air compressor, and dryer.
• · Maintaining plant lighting system, heavy-duty light fixing, light control timer and contactor switches, small lights, high bay light, and motion sensor control lights.
• · Maintaining cabling, alignment, and replacement of field devices like thermocouples, MOV, pressure sensors, mass flowmeters, limit switches, photosensors, solenoid switches, and operations of melting furnace, rolling mill, and coiling system.

• Maintained a safe work environment by strictly adhering to established safety protocols and guidelines.
• Trained new technicians on standard operating procedures, ensuring consistency across the team.
• Performed troubleshooting and diagnosis of malfunctioning equipment.
• Completed complex repairs quickly by leveraging strong diagnostic skills and attention to detail.
• Maintained meticulous records of maintenance activities, ensuring compliance with industry standards.

Develop and implement preventive, predictive, and reliability-centered maintenance (RCM) strategies to enhance equipment uptime and operational efficiency.

Creating work order management, scheduling, and resource planning.

Oversee and schedule shutdown and turnaround maintenance for HV/LV switchgear, transformers, motors, MCC panels, and electrical distribution systems.

Ensure spare parts availability and inventory control using SAP MM, coordinating with procurement to avoid stock shortages.

Conduct Root Cause Analysis (RCA) and Failure Mode & Effects Analysis (FMEA) for unplanned failures, improving equipment reliability.

Electrical Maintenance & Troubleshooting

Supervise and perform preventive and corrective maintenance on HV/MV/LV switchgear, transformers, motors, and industrial automation systems (PLC, SCADA, VFDs, Soft Starters, MCCs, etc.).

Implement and monitor condition-based maintenance techniques such as thermography, vibration analysis, partial discharge testing, and oil analysis to predict failures.

Troubleshoot electrical faults, control circuits, motor drives (Siemens, ABB, Allen-Bradley), and PLC-based systems to minimize downtime.

Ensure proper operation and maintenance of power factor correction panels, harmonics filters, and earthing systems for electrical stability.

Conduct load balancing, power quality analysis, and relay coordination studies for efficient energy management.

Supervision, Compliance & Safety

Lead and supervise a team of electrical technicians, planners, and contractors, ensuring adherence to best practices in electrical maintenance.

Implement LOTO (Lockout/Tagout), work permit systems, and HSE compliance to maintain a safe work environment.

Ensure strict compliance with ISO 55000 (Asset Management), NFPA 70E (Electrical Safety), IEC 60364 (Electrical Installations), and OSHA standards.

Conduct risk assessments, safety audits, and incident investigations, ensuring all electrical maintenance activities comply with industrial safety standards.

Budgeting, Reporting & Continuous Improvement

Prepare and manage CAPEX/OPEX budgets for electrical maintenance and asset replacement plans.

Monitor KPIs such as Mean Time Between Failures (MTBF) and Mean Time to Repair (MTTR) to drive maintenance efficiency.

Develop and present technical reports, failure analysis reports, and energy efficiency recommendations to senior management.

Drive continuous improvement initiatives (Kaizen, 5S, Lean Maintenance, Six Sigma) to enhance plant efficiency and cost-effectiveness.