Uthayakumar R Email & Phone Number

Chennai, Tn, In

Chennai Area, India

Since 2022, I've served as a Senior Engineer, specializing in PLM-MES Integration. My primary focus is on ensuring seamless connectivity between Teamcenter and MES applications, optimizing shop floor equipment functionality. Collaborating with cross-functional teams, I continuously explore technologies such as GitHub, Siemens Teamcenter, and Ford IIoT Systems. Additionally, I leverage controls software like TIA Portal and Rockwell Studio 5000 to enhance connectivity.In my role as a Maintenance Senior Engineer since 2018, I lead efforts to maximize equipment uptime and promote technical skill development within the maintenance team. Beyond day-to-day operations, I drive strategic initiatives aimed at improving equipment reliability and operational efficiency, including cybersecurity measures and asset inventory management.My dedication to continuous improvement and Industry 4.0 initiatives has led to significant achievements, including:1. Leading the on-site implementation of an IIoT Monitoring Application at Ford South Africa Plant - Body Shop, enhancing operational insights.2. Analyzing equipment condition through vibration and machine event monitoring, enabling proactive maintenance strategies.3. Implementing CNC Machines Axis Health Monitoring Data Analysis for predictive maintenance and downtime reduction.4. Spearheading IIoT projects, such as Kawasaki Robot Health Monitoring and Weld Tip Wear Analysis in the Body Shop, resulting in predictive maintenance capabilities.5. Winning the Ford Technical Excellence Award (TEA Y2019) for an IIoT project and TEA Y2020 for cost-saving modifications in Cylinder Head disassembly machines.6. Implementing low-cost IIoT solutions and paperless processes using innovative technologies like eWon gateway devices, Smart Manuals with QR codes, and RealWear smart glass with the Augmentir Application.I am passionate about driving innovation and leveraging technology to solve complex challenges in manufacturing.

Chennai Area, India

As a Maintenance Engineer since 2013, I've overseen maintenance operations within the machining area, focusing on equipment reliability and downtime reduction. Alongside managing maintenance activities, I ensure Manufacturing IT tasks, enhancing operational efficiency and data security. I prioritize continuous learning, empowering team members and fostering collaboration with engineering teams for successful project implementation.Key achievements include:1. Implemented Conformal Coating on PCBs, resolving recurring PCB failures in Crankshaft Deep Rolling machine.2. Introduced Servo Trace feature in CNC machines, predicting ball screw life and reducing quality concerns.3. Analyzed Siemens 840 Action Logs, identifying failure causes and implementing permanent fixes.Visited MAG IAS Company in USA, reducing maintenance issues on new CNC machines and preventing existing problems.4. Redesigned electrical panel for Cylinder Block Honing machine, preventing coolant contamination and ensuring uninterrupted operation.5. Diagnosed B-axis overcurrent fault in Cylinder Head CNC machine, leading to a warranty coverage agreement with the OEM.6. Improved machining line uptime by implementing filtration units, upgrading CNC machine components, and centralizing CNC file sharing for analysis.7. Selected for the LaunchPad Program, enhancing personal and professional growth.Through these accomplishments, I've demonstrated technical expertise and problem-solving abilities, contributing to the success and reliability of our maintenance operations.

Chennai, Tamil Nadu, India

Since 2011, I've served as a Maintenance Team Leader, overseeing a dedicated team of eight individuals focused on ensuring equipment uptime and smooth machinery operation. My role has evolved to include maintenance work planning, cross-functional team coordination, and report generation for management review, all while remaining actively involved in resolving critical breakdowns.Key achievements from my tenure include:1. Addressed collisions on CNC machines by identifying and correcting NC program bugs, permanently resolving the issue across multiple machines.2. Rectified a persistent loose connection issue in our gantry system, restoring production efficiency by identifying and fixing the elusive loose contact.3. Implemented an alternative safety system on the Block final washing machine, using a light curtain to replicate the functionality of a failed Sick Safety scanner, minimizing production downtime.4. Resolved a High-Pressure Pump failure in the final washing machine by identifying and replacing a malfunctioning bypass valve, enhancing machine reliability.5. Mitigated recurring electronics failures on the Crankshaft deep rolling and straightening machine by replacing burnt valve connections and implementing new pressure sensors and alarm systems.6. Resolved quality issues in parts produced by the Cylinder Head CNC machine by identifying natural frequency-related vibrations within the spindle and making modifications to the tool program.7. Prevented frequent tool breakages on a Cylinder Head CNC machine by identifying and replacing a faulty relay within the coolant system's Siemens Logo PLC, minimizing downtime and ensuring uninterrupted production.These experiences demonstrate my ability to tackle complex technical challenges and drive operational excellence, contributing to the continuous improvement of our organization.

Chennai, Tamil Nadu, India

As a member of the Machine Shop Maintenance Team, I play a crucial role in supporting equipment movement, installations, commissioning, and ongoing maintenance activities. My responsibilities span from developing preventive and predictive maintenance tasks to executing corrective maintenance activities and handling equipment failure analysis and supplier follow-up.I have extensive experience working with various Original Equipment Manufacturers (OEMs) including MAG Huller Hile, MAG Excello, Durr Ecoclean, Marposs, and more. Each machine breakdown presents an opportunity for learning and implementing corrective actions to address root causes effectively.Some notable achievements include:1. Implemented dual-channel safety for all equipment in the machining area, enhancing personal safety.2. Implemented error-proofing in High-Pressure engine components washing machines, improving washing effectiveness.3. Implemented "Auto Cycle enabled" feature in 4-station Intermediate washing machines, reducing operator wait time.4. Implemented interlocks on oil spray nozzle cylinders, preventing frequent nozzle breakage.5. Identified a small loose contact causing Y-axis servo alarm on a CNC machine, leading to a resolution after OEM investigation.6. Analyzed servo motor failure in a CNC machine, identified high coolant spillage as the cause, and recommended increasing the IP rating for Z-axis motors to the OEM.7. Corrected a PLC logic bug on Gantry systems, reducing failures in lubrication systems over the past 6 months.These experiences reflect my commitment to continuous improvement and ensuring the efficient operation of machinery in the maintenance domain.

Chennai Area, India

As a Maintenance Trainee at the Specialty Wheels Division, I embarked on a transformative journey in the realm of maintenance operations within the Aluminum alloy wheels manufacturing sector. This dynamic division encompassed a myriad of manufacturing processes, ranging from hot forging and wheel forming to pressing, furnace operations, turning, milling, polishing, washing, and backing processes. Additionally, my responsibilities extended to maintenance activities in the Wire Wheel Division, encompassing various special-purpose machines and Electroplating sections.During my tenure, I played a pivotal role in ensuring optimal equipment functionality through both breakdown maintenance and preventive maintenance strategies. A key aspect of my role involved instruments calibration activities, where I meticulously calibrated Thermocouples, RTD, PID controllers, Timers, and Ammeters, ensuring precise and accurate readings for operational efficiency.Throughout my experience, I had the privilege of working with esteemed OEMs such as Chiron CNC, Doosan CNC, Okuma CNC, and Fanuc Robots. Additionally, I gained valuable insights into a plethora of Industrial Control Systems, including Siemens PLCs, Drives, CNC systems, and Rockwell PLCs.Key Skills and Responsibilities:1. Proficient in PLC programming for Siemens S7-200&300, Allen Bradley, Fanuc, and Omron.2. Experience in Fanuc Robotics and interfacing with machining cells.3. Expertise in troubleshooting CNC and conventional machines.4. Hands-on experience with drives from Siemens, Allen Bradley, and Control Techniques.5. Familiarity with Hydraulic Press and Pneumatic control machines.6. Preparation and maintenance of machinery documents and spare maintenance.During my tenure as a Maintenance Trainee, I acquired invaluable skills and expertise that have laid a solid foundation for my career in maintenance engineering.

Coimbatore Area, India

After completing my studies, I embarked on an exciting journey with Suzlon Wind Energy, where I took on the role of a Wind Energy Monitoring Technician. My primary responsibility was to monitor the operational status of wind energy stations and meticulously record power consumption data.In the event of any station downtime, I promptly responded by conducting on-site breakdown maintenance. This often involved climbing up wind stations via ladder to address top-side faults, showcasing my dedication to ensuring uninterrupted energy production.During this enriching experience, I immersed myself in various aspects of industrial control systems, machinery, PLC, HMI, and work methods. Each day presented new challenges and learning opportunities, contributing to my professional growth and expertise in the renewable energy sector.

Bachelor Of Technology (B.Tech.), Electrical And Electronics Engineering

Diploma, Electrical And Electronics Engineering