MAHIPAL REDDY CHALLA

• Owner of the Reliability Excellence Practice, responsible for driving improvements and managing change to elevate the engineering team to world-class standards across various competencies. These include lubrication management, preventive and predictive maintenance, spare parts management, cost management, zero breakdown initiatives, and continuous skill development.
• Accountable for project management with oversight of an average $5M CAPEX annually. Possesses extensive expertise in facilities management, covering all utilities such as boilers, compressors, HVAC systems, and nitrogen, as well as energy management.
• Enhanced overall plant safety by implementing stringent safety protocols, Life saving practices and conducting regular audits.
• Achieved a reduction in plant breakdowns to below 0.8% and cut engineering operations costs by over 30% within two years.
• Established workplace organization (WPO) in the engineering store, completed annual inventory counts, and reduced inventory count variance through the implementation of SAP work orders, CCTV monitoring, and daily cycle counts.

Responsible for overseeing operations in the power house, including high-pressure boilers, air compressors, 33KV,2.4KV Substations, cooling towers, ventilation and refrigeration equipment, generators, and other related machinery typically found in an industrial plant power house.

Key achievements include the successful completion of a 3 MW rooftop solar system, the design and installation of a centrifugal compressor, an upgrade from HFE to CFE extruder, and the implementation of a new carbon black loading system. I also reduced full plant electrical consumption from 98,000 kWh/day to 75,000 kWh/day.

My role involves providing support, direction, and ensuring the reliable operation of primary systems within the facility. I manage the installation of plant engineering equipment and projects to support manufacturing operations, oversee day-to-day management and coordination of major plant and facility construction, installation, upgrades, and expansions, with a strong emphasis on safety, quality, maintenance, production, and security.

Additionally, I oversee the design, layout, and estimation for various construction and engineering projects to advance energy business objectives, while maintaining confidentiality regarding Goodyear specifications and technical information.

Coordinated all maintenance activities for the powerhouse and facilities equipment in collaboration with the powerhouse coordinator. Responsible for developing, planning, and scheduling preventive maintenance programs, ensuring adherence to established plans, procedures, and schedules based on superior targets.

Ensure that all regular inspections and audits of maintenance and operational activities in the powerhouse and facilities are completed accurately and on schedule. Assist with troubleshooting, major repairs, modifications, and upgrading/modernization of equipment within the powerhouse and facilities.

Support the superior in ensuring all equipment remains in safe operating condition, eliminating safety hazards, and maintaining good housekeeping practices in the powerhouse and associated work areas. Ensure that the team maintains all facilities equipment, including power vehicles and air-conditioning systems, in the most cost-efficient manner.

Establish career development plans, goals, and objectives for each direct report to foster continuous improvement in both individual and team performance.

Key accomplishments include the successful installation of VFDs for factory water pumps, cooling towers, hydraulic and ejector pumps, and centralized chiller optimization. Additionally, I installed a 10-ton fire tube boiler and increased its efficiency from 84% to 92%.

• Coordinate all maintenance activities for the powerhouse and facilities equipment in conjunction with the powerhouse coordinator. Develop, plan, and schedule preventive maintenance programs, ensuring compliance with established plans, procedures, and schedules to meet superior targets.
  
  Achieved zero steam drops and zero electricity failures over 2.5 years of powerhouse operation. Contributed to the design and installation of a 2.4 kV substation and facilitated the replacement of oil-type transformers with dry-type transformers. Installed high-efficiency boiler feed pumps, factory water pumps, and cooling water pumps. Additionally, played a key role in the design and installation of a new wastewater treatment plant and sewerage plant.

• Work with various PLC technologies and develop and update existing code for the equipment
• Provide and specify the equipment and hardware specifications required in the process of programming
• Assist in checking the Input and Output check points for the developed programs and making corrections in them if any
• Fixing troubleshoot problems in the systems, and the enhancements that support systems
• Make sure that end users are comfortable using the developed systems, assist them in using the systems.