Sumit Kumbhakarna

• Lead advanced process engineering initiatives aligned with APQP methodology, including PPAP documentation, PFMEA, control plan deployment, Measurement System Analysis (MSA), process capability studies (Cp/Cpk), and validation planning to ensure stable and repeatable manufacturing processes. • Manage greenfield and brownfield plant setup projects, including machine installation, automation integration, commissioning, process validation. • Optimize industrial engineering and manufacturing efficiency through manpower optimization, takt time analysis, line balancing, plant layout design, Yamazumi chart analysis. • Drive end-to-end new product and project implementation, including CAPEX, OPEX, REVEX planning, facility infrastructure planning, automation system deployment, and assembly line commissioning to achieve on-time project launch and operational readiness. • Oversee plant engineering and utility systems management, including maintenance and operation of DG, screw compressors, chillers, HVAC, STP, fire safety infrastructure to ensure high equipment availability and uninterrupted plant operations. • Ensure strict adherence to automotive quality and compliance standards including IATF 16949 requirements, ISO 50001 energy management systems, MSA guidelines, statutory regulations, and ESG compliance frameworks. • Spearhead assembly automation development and machine integration, encompassing hydraulics, pneumatics, electrical control systems, PLC programming (Omron, Mitsubishi, Delta), HMI configuration (Weintek), SCADA integration (Citect), servo drive systems, machine vision solutions (Keyence IV2/IV3, LabVIEW), and SQL-based data acquisition for End-of-Line (EOL) testing and validation. • Maintain industrial communication architectures including MODBUS (RTU/TCP-IP), Ethernet/IP, EtherCAT, and CAN protocols to ensure reliable machine-to-machine connectivity and seamless system-level integration across manufacturing lines.

• Planned and executed maintenance projects, ensuring timely completion of deliverables using Excel and Maximo/Max-Maintenance systems. • Monitored key maintenance KPIs including MTTR, MTBF, Breakdown %, and OEE, improving equipment reliability and uptime. • Coordinated weekly PMO and maintenance review meetings, tracking progress through AIS trackers and resolving critical issues. • Prepared and maintained project documentation, cost tracking, completion reports, and vendor invoices for effective budget control. • Forecasted maintenance costs and managed third-party vendors, installations, and purchase order processes. • Developed PM checklists, SOPs, method statements, and risk assessments aligned with plant operations. • Led maintenance KPI achievement and mentored technicians through training and skill development programs. • Supported API audits, ensuring compliance and reliability of assets. Managed vendor selection, procurement activities, cost optimization, and budget approvals. • Technical knowledge in process and testing of API equipment, including API 6A Hydraulic Valves and Gates, API 16C Choke & Kill Manifolds, API 16A BOP Testing, and API 7K Mud Pump Testing, Local Control Panel (LCP) systems, valve and actuator pressure testing, and ensuring compliance with API standards for oil & gas equipment manufacturing and testing. • Conducted Process Safety Risk Management using tools like MOC, PSSR, Incident Investigation, PHA, and Stop Work Authority. • Handled major breakdowns and maintenance of equipment including CNC machines (Doosan, Hartford, Jyoti, MAZAK), hydraulic fixtures, EOT cranes, forklifts, compressors, DG sets, furnaces, welding machines, lapping and grinding machines.

• Managed Preventive, Predictive, and Breakdown Maintenance of CNC machines to ensure maximum equipment availability and productivity. • Planned and executed maintenance schedules through SAP PM, including work order generation, tracking, and closure. • Diagnosed and resolved critical machine breakdowns involving CNC, HMC, VMC, robotics, and auxiliary equipment. • Monitored minimum and maximum spare inventory levels through regular store audits to reduce downtime risk. • Supervised installation, alignment, and commissioning of machine components such as spindles, gearboxes, ATC systems, conveyors, and hydraulic/pneumatic systems. • Conducted root cause analysis (RCA) for major breakdowns and implemented corrective actions to prevent recurrence. • Maintained proper documentation of maintenance activities, reports, and technical records for continuous improvement and audit compliance