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The HEINEKEN CompanySenior Preventive Maintenance Manager (Maintenance Champion)
May. 2023IBExpertise in leading cross-functional teams, optimizing equipment performance, and implementing preventive maintenance strategies to reduce downtime and increase operational efficiency. Proficient in managing budgets and ensuring safety and regulatory compliance. By leveraging data-driven insights as drives for continuous improvement in line with Maintenance Best Practices, enhancing asset management and operations efficiency.
• Provided leadership and coaching to the maintenance team towards implementation of 5S, IL6S-Integrated Lean 6 Sigma ways of working, delivering zero breakdowns via preventive/predictive maintenance strategies and technical mastery of maintenance and operations teams, PM (Progressive Maintenance) Pillar, and CBM (Condition-Based Monitoring), Visual controls & tools management, and Lubrication management & Calibration of equipment(s), etc.
• Developed detailed project plans, schedules, and budgets, managed resources effectively to meet project milestones and financial targets, and utilized project management software to monitor project progress, track key performance indicators, and generate stakeholder status reports.
Keys Achievements.
• Implemented process continuous improvement that increased production efficiency by 25%, reduced costs by 15%, and enhanced product quality.
• Reduced overhaul maintenance costs by 15% through negotiation with crucial vendor contracts while maintaining quality services.
• Developed and implemented a preventive maintenance program, increasing equipment efficiency from 62% to 92%.
• Anchored critical equipment upgrades that enhanced production capacity by 15% and increased deliverable output.
• Successfully reduced equipment downtime from 25% to 5% over one year by implementing a structured, proactive maintenance program.
• Increase equipment lifespan with regular maintenance activities, including lubrication, calibration, and parts replacement, extending the lifespan of critical machinery by an average of 20%.
The HEINEKEN CompanyPlant Maintenance Manager (Energy & Water Champion)
May. 2017 - May. 2023KDOversee high-performing preventive maintenance team, operation staff, and labor services accountable for mechanical, electrical, and electronics diagnostics, repairs, fabrication, and construction, generating and distributing water, effluent water treatment, glycol, steam, condensate, air, CO2, cooling, installation of machines and equipment, and assets management, while driving optimal performance and minimizing downtime,
• Established structure predictive and preventive maintenance strategies in managing the equipment reliability and the operations of Boilers, Burners, Air Compressors, Ammonia Compressors, CO2 Compressors, CO2 Liquefaction Compressors, Vaporizers, Evaporative Condensers, Chillers, Pumps, Plate Heat Exchangers, Water Treatment Plant, Waste Effluent Treatment Plant, Cooling Towers, Hydraulic/Pneumatic tools, and utility materials handling. • Responsible for the preventive maintenance and operations of the Water treatment plant (Service Water, Process Water, and Carbonated Water) and Wastewater treatment plant (Sedimentation, Screen Press. Oil Skimmer, Calamity Tank, Equalization Tank, UASB – Up-flow Anaerobic Sludge Blanket, (Biogas Generations) SBR – Sludge Back Reaction, and Chlorination Pit).
• Coordinated the preventive maintenance of Brewing process equipment, (Silo Equipment, Intake Pit Radler Conveyor, Grain Silos, Pneumatic Valves, Bucket Elevators, Cyclone dust, Key Achievements. • Implemented cost-saving initiatives in managing utility machines and equipment by optimizing overall running 15% uptime, quality, and safety.
• Spearheaded an energy efficiency improvement and overhaul that cut utility costs by 15%, streamlining budget adherence to business objectives.
• Optimization of brewing equipment's overall running time from 95% utilization to 85% usage reduction to save energy consumption.
• Developed a cross-training program that increased maintenance and operational team efficiency resulting in a 10% reduction in labor costs.
The HEINEKEN CompanyMaintenance Manager (Machines & Equipment)
Apr. 2013 - May. 2017ENResponsible for the maintenance of bottling machines (Krones, KHS, SIDEL, and Tetra Pak), and equipment and imparting knowledge, evaluating, and developing the skills of the maintenance teams. (De-palletizer, Palletizer, Packer, Unpacker, Crate/Bottle Washer, Filler, Pasteurizer, Labeler, Blow Moulder, Filler-Capper-Rinser, Flash/Tunnel Pasteurizer, Robo-pack, Shrink Wrapper and Sealer).
• Structured maintenance plan encompassing daily, weekly, monthly, quarterly, and yearly activities, and directing the workload on planned downtime and interruptions must be maintained at an absolute minimum.
• Successfully coordinated and scheduled maintenance activities, consistently delivering projects on time and prioritizing work orders to optimize productivity.
• Implemented maintenance programs (Periodic Inspection, Preventive & Major Overhaul) for the machines and equipment to ensure optimum availability, and reliability to reduce downtime and increase production efficiency.
• Coached and supported with hands-on knowledge of the maintenance process with an understanding of methods of reliability of machines and equipment, repairs, root cause analysis, and loss elimination.
• Administered autonomous maintenance at the packaging/production section with full-time support from SME, AM/PM teams, TPM, UPS, 5S, 4M, Kaizen, focus improvement, and lean methodologies. Key Achievements.
• Revitalized the maintenance scheduling system, which improved the on-time completion of maintenance tasks from 62% to 92%.
• Launched a continuous improvement program that increased machinery life by 25%, leveraging the lean methodologies principle.
• Facilitated team-building initiative that improved maintenance & production team collaboration and reduced cross-functional conflict by 10%.
The HEINEKEN CompanyMaintenance Planner Mgr. (Process Champion)
Feb. 2012 - Apr. 2013ABAnchored all engineering policies implementation, regulations, controls, CMMS process compliance, all documentation, spare parts management, and inventories of machines and equipment to minimize downtime and cost-saving optimization and machine utilization,
• Audited inventories of spares management to identify the common items across the plant, and fix inventory norms with MRP settings for fast-mover, slow-mover, medium-moving, and obsolete items.
• Conducted in-depth analysis with CMMS and reporting structured on preventive maintenance activities backlogs, work order flow, notification, tagging, and DE-tagging, with estimated completion time, and vibration analyses reporting.
• Work closely with the maintenance engineer to develop and communicate relevant KPIs for the maintenance teams, PPM compliance percentage, overdue PMs, schedule adherence, MTBF, and percentage of PdM executed.
• Provide weekly and monthly updates on spare management inventory reports to the key stakeholders for effective decision-making on replenishment.
• Follow up with new updates on documentation of equipment and machinery, policies, procedures, regulations, fire protection- systems, and controls. Key Achievements.
• Overhauled the spare parts inventory management, which decreased the surplus inventory level by 25%. • Streamlined cross-departmental workflow, boosting team productivity by 20% through effective implementation of lean principles.
• Facilitated a 5% increase in resource utilization efficiency through detailed analysis and reporting.
The HEINEKEN CompanyShift Maintenance Manager (Packaging/Production)
Feb. 2009 - Feb. 2012ABManaged shift preventive maintenance activities, repairs, first-level maintenance, coaching, and mentorship, reviewing performance, giving employee feedback, and building interpersonal skills and positive relationships with teams,
• Provide technical expertise to troubleshoot and resolve complex maintenance issues on production equipment and machinery.
• Lead and supervise the maintenance team to ensure all equipment and production machinery are operating efficiently and safely • Investigated and resolved packaging equipment and machinery failure issues, implementing solutions to prevent future occurrences.
• Monitored KPIs daily, weekly, and monthly to ensure on-track and analyze packaging/production process data trends to identify areas of opportunities and develop continuous improvements.
• Restructured the maintenance and packaging team to foster a high-performance culture, leading to the achievement of record-breaking operational efficiency targets. Key Achievements. • Coordinated shift maintenance team on production lines to achieve a 15% increase in overall equipment effectiveness (OEE).
• Conducted cost-benefit analysis of different packaging materials, resulting in a 10% reduction in packaging costs.
• Collaborated with cross-functional teams AM/PM to implement packaging changes, leading to a reduction in packaging costs by 15%.
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