VYSHNAV RANJITH

Contributed to pre-operational planning activities for a new manufacturing facility, supporting maintenance framework development, equipment documentation review, and automation system preparation.

• Reviewed equipment specifications, layouts, and maintenance documentation to support upcoming plant setup activities.
• Assisted in developing preventive maintenance structures and asset management planning for future operations.
• Coordinated with engineering and project stakeholders during early-stage planning discussions.

Provided technical support and advisory services for industrial machinery and automation-integrated systems, contributing to SPM development, machine building guidance, performance troubleshooting, and cost estimation for manufacturing projects.

• Delivered technical consultancy for industrial machinery and automation-integrated systems, contributing to Special Purpose Machine (SPM) development, machine building support, and performance optimization projects.
• Evaluated mechanical designs, hydraulic and pneumatic systems, and automation interfaces to ensure technical feasibility, system integration, and operational reliability.
• Conducted advanced troubleshooting and Root Cause Analysis (RCA), while preparing technical proposals, project scopes, and cost estimations aligned with client performance and commercial objectives.

Joined as Assistant Engineer in 2016 and progressed into expanded responsibilities within plant maintenance, automation integration, and execution of large-scale commissioning and engineering projects, leading major technical initiatives from 2021 onward.

• Directed daily plant operations, ensuring reliability of moulding machinery, utilities, and auxiliary equipment in compliance with HSE and ISO standards.
• Coordinated with production, quality, and procurement teams to align maintenance activities with business objectives and minimise operational disruptions.
• Prepared technical documentation, SOPs, and audit reports, supporting ISO 9001:2015 and HACCP certifications while ensuring audit readiness.

Key Achievement & Projects

• Retrofitted 17 high-tonnage injection moulding machines (450–1800T) by integrating Yuken ASR and Delta HES servo systems, delivering 65% energy savings with ROI achieved within 8–9 months.
• Executed end-to-end installation and commissioning of large-scale injection moulding (up to 2200T) and blow moulding machines (up to 100L),ensuring OEM compliance and adherence to ISO 9001 standards.
• Designed and implemented a Special Purpose Machine (SPM) – Pool Ball Water Filling Machine, which enhanced production capacity by 70% (9,000 pcs/shift) and optimised cycle time.
• Engineered and deployed a hydraulic and pneumatic rail system for cement wall manufacturing, boosting plant productivity by 30% and reducing manual intervention.
• Re-engineered and upgraded hot stamping machines, increasing production efficiency by 35% while ensuring consistent product quality.
• Refurbished and recommissioned a 10T EOT crane, extending operational lifecycle, improving safety standards, and aligning with HSE compliance.
• Implemented a structured preventive and predictive maintenance programme, reducing downtime by 50%, improving MTTR/MTBF, and extending equipment lifecycle.
• Conducted detailed Root Cause Analysis (RCA) and implemented Corrective and Preventive Actions (CAPA), significantly reducing repeat failures and improving operational reliability.
• Directed and delivered multiple SPM development projects, ensuring seamless integration into production lines and improving throughput and product quality.
• Represented the Maintenance Department during ISO 9001:2015 and HACCP audits, achieving 100% compliance and successful certification outcomes.
• Developed and delivered comprehensive technical training programmes for operators and technicians, enhancing workforce capabilities in troubleshooting, machine operation, and preventive maintenance.
• Spearheaded energy optimisation initiatives and retrofit projects, aligning operational strategy with Industry 4.0 and sustainability goals.

Supported maintenance operations for capacitor ageing machines in an electronics manufacturing environment, focusing on equipment stability and downtime reduction.

• Executed preventive and corrective maintenance on capacitor ageing machines, diagnosing mechanical and electrical faults to ensure stable operation and minimize unplanned downtime.
• Maintained maintenance records, spare part tracking, and supported routine inspections to improve equipment reliability and operational consistency.