Balaji K J

Experience

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  Rane Engine Valve Limited (REVL)

  Nov 2003 - Dec 2005

  Maintenance Trainee

  Maintenance Trainee- Hands on experience in Plant & Utility maintenance. Maintained equipment's such as- Hot forging screw rod presses, Friction welding, Up-setters, Centrifugal grinding, Precision Lathe, Furnace, Compressor, Generators, Cooling tower.

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  Wheels India Limited

  Jan 2006 - Nov 2009

  Junior Engineer- Maintenance

  Maintenance shift in-charge: Maintained equipment such as- Heavy duty presses: 1200T, 1500T, 250T, 100T, Hydraulic presses-800T, 600T, 400T, Screw rod press- 1000T, MIG Welding machines, Butt Welders, Roll Forming, Vertical Boring machine etc .

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  Unipres India Pvt Ltd

  Nov 2009 - Jul 2010

  Maintenance Engineer

  Setup new plant Green field project, Developed standards related to Maintenance, Maintenance shift incharge taking care of KOMATSU Transfer press 2500T, KOMATSU Blanking Press line 600T, ISGEC Die spotting press, Body shop fixtures, Manual Weld guns, DEMAG EOT Cranes & complete Utilities equipment's

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  TVS - SUNDARAM BRAKE LININGS

  Aug 2010 - Jun 2011

  Junior Manager- Maintenance

  Maintenance In-charge: Taking care of plant maintenance & utilities. Improved equipment up time, productivity improvement, new equipment erection. Maintained equipment such as Hydraulic presses- 100T, Mixing machine, SPM grinding machine, SPM drilling machine, Thermopac Furnace, Generators, Compressors & Cooling towers. Budget planning & execution.

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  Ford Motor Company

  Jun 2011 - Dec 2022

  Expertise in press shop maintenance - Transfer press, Blanking press, Mechanical presses, Hydraulic press. Robotic Maintenance in KUKA, ABB, Crossbar servo feeders.Six sigma green Belt projects: (Ex.)- Y2021: B515 Dash Die - Energy saving done in 1P - Y2020: Scrap cost reduction in Dash draw panel (Part of Black Belt); Elimination of B515 FDI Panel drop issue- Y2019: Elimination of Vacuum Switch failure- Y2018: Scrap cost reduction in Door Inner & Body side outer panel (Part of Black Belt)Key Milestones:- Global Manufacturing Technical Excellence Award (TEA) for Anti Collision for CT and LT to enhance crane safety in SBU- President’s Health Safety Awards (Regional) for performing Die Bolt Error Proofing in Try out Presses- Global Manufacturing Technical Excellence Award (TEA) participated Automatic Variant changeover - Plant wide best work-group winner (3rd price) for improving throughput in KOMATSU Press line Show less Maintenance Shift In charge: Handled Equipment's such as SCHULER Press line (1800T, 1000T-5 no's), KOMATSU Press line crossbar servo feeder (2500T, 1600T, 1000T-3 no's), FAGOR Blanking line (600T), ESMECH Blanking Line (500T), ABB dropin Robots, KUKA Robots, FAGOR Die tryout press (1500T), MECOF Milling machine, HBM Machine, Tool room equipment's, Blank Indexing machine, EOT Cranes 50T & 15T, 32T & 10T, Coil hangers, Coil Lifters, Die grabber EOT Crane 65T, Die carts, JLG Scissor lifts etc...- Lead Major maintenance activity every YOY during block closure days. • NC Die Cushion cylinders seal replacements, Gib pad liners replacement. Servo Valve replacement, Analysis with supplier for failures root cause. Maintained oil NAS level 5/6.• Press slide overload system seals & O ring replacement. Press Crown main gear inspection. Press counterbalance cylinder seal replacement. Press Main motor 500KW bearing replacement & Entire motor replacement. Moving Bolster Drive replacement, AC Motor & gearbox replacement.• Blank washer: Squeeze roller replacement, Roller relining & reuse with cost optimization, Feed roller replacement, Monitoring of oil qty for alll parts & reduced excess oil delivery. Dirt control implemented to reduce bumps & dents.• Dry Clutch & Brake clearance correction, Wet Clutch & Brake seal replacement & oil leakage correction. Safety Ross valve replacement & Internal overhauling. • Servo Feeder Ball screw replacement, LM guide replacement, Servo motor replacement. Harmonic drive gear set replacement, RV reducer for swing axis replacement. Servo amplifier replacement. • Robotics periodic maintenance activity of replacing gear box oil, Timer belt replacement for specific axis, Crossbar alignment, Drive & battery replacement.• End of line conveyors Belt replacement 1.8mtr width x 43mtr long, 1.8Mtr width x 9mtr long. 1.8Mtr width x 6mtr long. Cyclo drive gearbox replacement.• Front of line belts & rollers replacement, position issues correction Show less

  • Sr. Engineer in Press Maintenance at FORD India pvt ltd

    Oct 2015 - Dec 2022

  • Engineer in Press Maintenance at FORD India pvt ltd

    Jun 2011 - Sept 2015
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  Gestamp

  Aug 2023 - now

  Maintenance Manager

  Hot stamping press line.Laser, Weld shop, Robots, Furnace,Utilities etc…