Amrendra Kumar

B.E Mechanical; PMP®, CSM®, CSPO® ,CMRP®

PROFILE SUMMARY

Bringing over 20 years of progressive experience in mechanical maintenance, project planning, shutdown execution, reliability engineering, and cross-functional leadership in large-scale oil & gas operations including Gasification, FCCU (world’s largest olefin unit) and Polypropylene (PP) plants licensed by Dow Chemicals, USA.
Led multidisciplinary teams & coordinating large-scale shutdowns, revamps, and reliability projects, ensuring zero unplanned downtime and compliance with HSE and operational excellence standards.
Steered static & rotary equipment maintenance like overhauling, diagnostics & reliability engineering of pumps, compressors, exchangers, turbines, fans, columns & heaters.
Led project execution & commissioning, contributing to expansion of refinery assets, including polyolefin units, FCCU & gasification blocks at Reliance Industries’ flagship site.
Led planning and execution of MOCs, preventive maintenance, and inspections using integrated systems such as SAP-PM, SAP-MM, MMCS, and Primavera P6.
Adept in digital transformation of maintenance processes, leading adoption of tools for schedule optimization, job packs, BOM accuracy & data-driven decision-making.
Certified PMP®, CSM®, & CSPO®, CMRP®combining structured project management discipline with Agile principles to improve maintenance turnaround cycles and team agility.
Drove cost-effective material management, vendor negotiations, inventory controls, and critical spares strategy aligned with equipment lifecycle performance.
Experienced in cross-functional coordination with planning, procurement, engineering, QA/QC, and operations to bridge planning gaps and enable flawless field execution.
Passionate about building high-performance teams through knowledge transfer & technical training, contributing as a certified faculty member at RIL Learning Centre.
Committed to fostering a culture of compliance and safety, actively involved in IMS/PSM audits, work permit systems, and adherence to global maintenance standards.

WORK EXPERIENCE

Reliance Industries Ltd.

Key Responsibilities & Expertise

Mechanical Maintenance & Turnaround Leadership

Leading E2E maintenance planning & execution for Gasification units, with excellence in shutdowns across Crude, Hydro-treater, Coker, Aromatic, VGOHT, DHDS, and FCC units.
Driving OMS and HSEF compliance across all maintenance operations with strong focus on PSM, WPS, and statutory adherence.
Executing preventive & corrective maintenance of static & rotary equipment, including centrifugal/reciprocating pumps, steam turbines, exchangers, columns, tanks, fin-fan coolers, and heaters.
Overseeing overhauling & refurbishment of key equipment—tube bundle replacement, air cooler re-tubing, valve servicing, and pressure safety valve inspections.

Planning, Scheduling & Digital Integration

Leading detailed maintenance planning using Primavera P6, Microsoft Project, SAP-PM, and SAP-MM tools to align with organizational KPIs and minimize backlog.
Developing integrated job plans and digitalized turnaround schedules across multiple operating areas.
Driving adherence to asset integrated plans, facilitating seamless alignment between planning and field execution.
Coordinating weekly, 4-week, and outage-based schedules for all corrective, preventive, and inspection-related work orders.

Resource, Material & Inventory Management

Ensuring end-to-end planning, sourcing, cataloguing, and readiness of components required against work orders using SAP and MMCS.
Interfacing with procurement, material coordination, and buyer teams to resolve technical queries, ensure material readiness, and manage vendor negotiations.
Leading estimation and budgeting activities, risk analysis, and resource allocation across MOC jobs and shutdowns.

Leadership, Training & Stakeholder Collaboration

Managing a cross-functional maintenance team; setting performance expectations, mentoring, tracking KPIs, and driving continuous process improvements.
Coordinating with plant operations, QA/QC, safety, inspection, procurement, and contractor teams for job pack execution and compliance assurance.
Facilitating the development and succession planning of the Turnaround organization; certified internal auditor for IMS and PSM.

Technical Competency

Well-versed in P&IDs, PFDs, isometric drawings, equipment datasheets, piping/ structural layouts, and international codes & standards (API, ASME, ASTM, etc.).
Hands-on experience with equipment history tracking, work order management, BOM/SPIR generation, and reliability improvement initiatives.

Since Dec’22: Deputy General Manager – Mechanical Maintenance & Turnaround Lead

Spearheading mechanical reliability initiatives & leading the execution of maintenance strategies for Gasification units during scheduled shutdowns and turnarounds (SD/TA).
Strategically directing implementation of Operations Management System (OMS) and global HSEF protocols to ensure zero-harm culture and operational discipline.
Driving end-to-end planning and execution of Management of Change (MOC) projects, aligning with business continuity and equipment reliability goals.
Leading CAPEX/OPEX budget development and control for mechanical maintenance and improvement projects.
Orchestrating cross-functional coordination for scope finalization, job packaging, and contractor mobilization for critical shutdown activities.
Enabling digital transformation of maintenance operations through SAP-PM/MM and MMCS platforms, enhancing transparency and work traceability.

Jan’15 – Jan’22: Senior Manager – Mechanical Planning & Reliability Operations

Formulated robust maintenance strategies integrating condition-based, preventive, and predictive maintenance to optimize equipment uptime and lifecycle.
Designed comprehensive job plans with cost, material, manpower, and risk metrics for corrective maintenance and statutory shutdowns.
Developed standardized Work Packs including SMPs, QA/QC guidelines, and HSEF checklists to ensure regulatory and operational compliance.
Constructed 4-week and rolling maintenance schedules, driving backlog reduction and improving task adherence through periodic KPI reviews.
Managed strategic spares planning using SAP, ensuring critical inventory availability while minimizing carrying costs.
Mentored teams on SAP utilization, BOM creation, SPIR development, and data accuracy to support effective spare management and job tracking.
Championed structured RCA (Root Cause Analysis) and R&I (Reliability & Integrity) initiatives, converting insights into actionable maintenance practices.
Instituted HSEF documentation discipline (MIQA, CFA, RESOP), integrated contractor safety management, and ensured Process Safety compliance.

Jul’08 – Jan’15: Manager – Maintenance Lead (FCC Unit)

Led maintenance planning and execution of Fluid Catalytic Cracking (FCC) and PRU assets during refinery expansion phase, ensuring operational excellence.
Diagnosed equipment breakdowns using RCA and executed permanent corrective measures to prevent recurrence.
Managed turnaround logistics, resource planning, and schedule adherence for large-scale static and rotary equipment overhauls.
Embedded Lean practices and 5S methodologies across maintenance operations for sustained workplace efficiency.

Feb’06 – Jul’08: Manager – Maintenance & Projects (PP Unit)

Directed plant-wide maintenance planning for polymer production units involving static and rotary equipment, hydraulic systems, and critical utilities.
Executed mechanical installation and commissioning of major plant machinery including pumps, exchangers, blowers, and specialized vessels.
Oversaw structural and piping fabrication activities ensuring QA/QC alignment and adherence to commissioning timelines.
Facilitated integration of new assets into plant operations with structured handover and performance validation protocols.