Haryono Nugroho
Facility Maintenance Engineering Manager
West Cikarang,West Java
Summary
Dynamic Maintenance Manager with a proven track record at PT.TNA, PT.Changshin, PT.Mattel Indonesia, excelling in operations management and team building. Spearheaded initiatives that reduced downtime by over 12%, while ensuring PM adherence above 98%. Expert in TPM and energy management, adept at fostering cross-functional collaboration and driving significant improvements in productivity and cost reduction.
Overview
21
21
years of professional experience
1
1
Certification
Work History
Maintenance Manager
PT.TNA
Karawang
02.2023 - 09.2024
- Company Overview: Tuffindo Nittoku Autoneum, an automotive parts manufacturer (damper, insulation, dashboard heat, and sound absorption).
- Managed 18 technicians, 2 leaders, 1 staff administrator, and 1 supervisor for the maintenance of production machines, hot press, utilities, building, and their daily activities.
- Developed Total Productive Maintenance, Preventive Maintenance, Predictive Maintenance, and Corrective Maintenance procedures for all machines used in production.
- Established a system to track inventory of spare parts, minimum and maximum stock, critical parts, slow and fast moving tools, and supplies.
- Ensured compliance with safety regulations and standards, ISO 45001.
- Drafted annual budgets for maintenance operations and monitored expenditures, Opex, and Capex.
- Recruited and trained new employees to meet job requirements, and developed the structure of the organization in the Maintenance Department for TPM, corrective, preventive, utility, improvement team, and balancing 60% permanent skilled people and 40% non-permanent.
- Organized work orders, assigned tasks to staff members and tracked progress of repairs and maintenance projects.
- Recommended upgrades or modifications to existing systems based on analysis of data.
- Performed troubleshooting on malfunctioning systems when necessary, provided technical support in case of system malfunctions or breakdowns.
- Led the implementation of CMMS by implementing TPM, scheduling PM, predictive maintenance, overhaul, and regular replacement regarding life cycle management, and managing inventory of critical spare parts, and coordinating with vendors to purchase replacement parts as needed to reduce downtime by over 12% yearly, with PM adherence over 98%, increasing MTBF by over 12% yearly.
- Developed and implemented an energy management program to maintain KPI electric intensity at 2.5% and save 0.5% after 6 months, maintain gas intensity at 0.86% monthly, and water intensity at 4% monthly.
- Developed skilled technicians by setting up a curriculum regarding skill matrix competencies, delivered 75 hours of training monthly, promoted a safety culture to maintain zero accidents, and complied with ISO 9001, IATF, and ISO 45001, while promoting a 5S audit score greater than 85 monthly as a basic manufacturing standard.
- Planned and led team meetings to review KPI business results, and communicate new and ongoing priorities.
- Reviewed employee performance and provided ongoing feedback and coaching to drive performance improvement.
Sr. TPM Maintenance Manager
PT.Changshin Indonesia
Karawang
01.2022 - 12.2022
- Company Overview: Nike Shoes manufacturer
- Supervised 187 technicians, one manager, four assistant managers, and seven staff members.
- Established procedures for Total Productive Maintenance, Preventive Maintenance, Predictive Maintenance, and Corrective Maintenance.
- Created an inventory tracking system for spare parts, stock levels, and critical components, coordinating with vendors to purchase replacement parts as needed.
- Adhered strictly to safety regulation standards.
- Developed annual budgets for maintenance operations and tracked expenditures, Opex, and Capex.
- Recruited and trained new employees to meet job requirements, and developed the structure of the organization in the Maintenance Department for TPM, corrective, preventive, utility, and improvement teams.
- Organized work orders, assigned tasks to staff members and tracked progress of repairs and maintenance projects.
- Recommended upgrades or modifications to existing systems based on analysis of data.
- Performed troubleshooting on malfunctioning systems when necessary, provided technical support in case of system malfunctions or breakdowns.
- Developed skilled technicians by setting up a curriculum regarding skill matrix competencies, promoted a safety culture to maintain zero accidents, and complied with ISO 9001, and promoted a 5S audit score greater than 85 monthly as a basic manufacturing standard.
- Planned and led team meetings to review KPI business results, and communicate new and ongoing priorities.
- Reviewed employee performance and provided ongoing feedback and coaching to drive performance improvement.
- Led the implementation of CMMS Maximo by implementing TPM, scheduling PM, predictive maintenance, overhaul, and regular replacement regarding life cycle management, and managing inventory of critical spare parts, and coordinated with suppliers to ensure a reduction in downtime of 12% yearly by maintaining PM adherence above 90%.
- Collaborated with American consultant to establish KPI in maintenance.
- Addressed and resolved issues collaboratively across teams daily.
- Scheduled cross-departmental 5S as core manufacturing deep cleaning, to ensure asset maintenance.
- Produced thorough, accurate and timely reports of project activities.
Maintenance Manager
PT.Mattel Indonesia
Jababeka
06.2016 - 12.2021
- Company Overview: Fashion Dolls, toys manufacturer (Barbie, Hot Wheels).
- Oversaw 36 technicians, six leaders, one maintenance engineer, and one admin, supervised the maintenance of 250 injection molding machines, 10 painting lines, die cutting, laser cutting, digital printing, rotocasting, die casting, and Tampo BBD.
- Recruited maintenance staff to strengthen the organizational structure in the Maintenance Department for both Plant 1 and Plant 2.
- Achieved PM adherence exceeding 98%, and availability above 90% through lifecycle management, regular replacement, and TPM strategies.
- Optimized Bluetag management and Autonomous Maintenance practices.
- Designed an inventory management system for spare parts, tools and supplies.
- Coordinated meetings with cross-department teams for progress updates.
- Cultivated a strong safety culture through LOTO practices, conducted regular 5S audits to ensure sustainability, maintaining scores above 3.5 out of 5.
- Developed the Injection Molding Excellence program to enhance quality maintenance, which reduced NG parts by 4%.
- Achieved 54% reduction in electric consumption by replacing electric motors with servomotors for injection molding machines.
- Enhanced facility maintenance operation efficiency and optimal business performance by reducing variable costs, reducing 6 technicians for preventive maintenance, and making a service contract for preventive maintenance with the vendor, saving $15,800 per year.
- Achieved a 10% yearly reduction in operational expenditures.
- Replaced 20 underperforming injection molding machines with new ones, achieving annual productivity savings of $270,000.
- Frequently replaced screw barrels per 10 units, leading to $410,000 in annual savings.
- Drafted annual budgets for maintenance operations and monitored expenditures, Opex, and Capex.
- Supervised installation, repair and upkeep of machinery and mechanical equipment.
- Conducted regular training sessions for maintenance personnel on safety protocols and best practices.
- Organized work orders, assigned tasks to staff members and tracked progress of repairs and maintenance projects.
- Recommended upgrades or modifications to existing systems based on analysis of data.
Engineering & Maintenance Manager
PT.Drymix Indonesia
Cikupa
12.2014 - 06.2016
- Company Overview: Drymortar instant cement manufacturer at 4 site plant
- Led team of 16 technicians and 1 Maintenance Supervisor in overseeing production machinery upkeep of 4 sites plant.
- Recruited employees to enhance the organization's maintenance structure.
- Promoted a safety-first culture through structured guidelines, and implemented 5S methodology to enhance workplace organization.
- Ensured Preventive Maintenance adherence exceeded 95% and availability surpassed 90%.
- Conducted feasibility study to reduce operating costs for project, for example by installed sand dryer machines, installed auto bag packer machines.
- Executed study on operating cost reduction for automation systems in mortar cement manufacturing by conducted benchmark analysis for China Factories.
- Worked with consultant to enhance design and manufacturing efficiency in Cikupa Factory.
Assistant Preventive Maintenance Manager
PT.Danone Dairy Indonesia
Delta Silicone
01.2013 - 11.2014
- Company Overview: Aseptic Dairy Milk manufacturer
- Overseeing Preventive Maintenance team in aseptic dairy environment.
- Developed Total Productive Maintenance and Preventive Maintenance procedures for all aseptic machines used in production.
- Established a system to track inventory of spare parts, tools and supplies.
- Ensured compliance with 12 basic safety regulations and standards.
- Drafted annual budgets for maintenance operations and monitored expenditures, Opex, and Capex.
- Conducted regular training sessions for maintenance personnel on safety protocols and best practices.
- Organized work orders, assigned tasks to staff members and tracked progress of repairs and maintenance projects.
- Recommended upgrades or modifications to existing systems based on analysis of data.
- Performed troubleshooting on malfunctioning systems when necessary.
- Provided technical support in case of system malfunctions or breakdowns.
- Planned and led team meetings to review KPI business results, and communicate new and ongoing priorities.
- Reviewed employee performance and provided ongoing feedback and coaching to drive performance improvement.
Improvement Consultant
PT.Sentral Sarana Technology
East Jakarta
05.2012 - 01.2013
- Company Overview: Consultant ISO, Improvement
- Assisted in developing new methods for data collection and analysis techniques.
- Developed and implemented customized strategies to meet client needs.
- Created comprehensive reports on project progress and results for clients.
- Provided advice on operational processes, business development initiatives, organizational changes and other areas of improvement.
- Created plans to propose solutions to problems related to efficiency, costs or profits.
- Analyzed key performance indicators to identify effective strategies.
Maintenance Supervisor
PT.Royalboard
Lemah Abang
10.2010 - 05.2012
- Company Overview: Plasterboard manufacturer
- Scheduled and coordinated preventative maintenance activities to ensure equipment reliability.
- Monitored and evaluated the performance of personnel in the maintenance department, providing guidance and coaching when necessary.
- Ensured that safety regulations were followed by employees while performing maintenance tasks.
- Reviewed work orders, allocated resources, assigned tasks, and established priorities for completion of jobs.
- Supervised technicians on repair and installation of machines or systems according to manufacturer's specifications.
- Maintained records of repairs and parts inventory usage to optimize future planning efforts.
- Created detailed reports on machine downtime, root cause analysis, cost savings initiatives, and other relevant metrics related to production efficiency.
- Prepared budgets for upcoming projects based on estimated labor costs and materials needed.
Workshop & Engineering Manager
Rizky Jaya Persada
Cileungsi
06.2007 - 07.2010
- Company Overview: Workshop, machine maker
- Managed a team of 1 engineers, 1 workshop head, 33 technician delegating tasks and monitoring progress to ensure quality control standards.
- Created detailed reports for General Manager on the status of projects and deadlines.
- Coordinated with other departments to ensure product prototypes were completed in a timely manner.
- Established relationships with vendors to obtain materials at cost-effective prices.
- Prepared budgets for each project and monitored expenditures to stay within financial limits.
- Collaborated closely with marketing team to develop promotional materials highlighting new products.
- Maintained comprehensive records of engineering activities, including test results, design specifications, changes made during development process.
- Generated concept designs, collaborated with customers to gain feedback and directed entire design process.
- Managed the engineering project lifecycle from concept through to production, improving project completion rates.
Maintenance Supervisor
PT.Wavin Duta Jaya
Cikarang Barat
02.2004 - 05.2007
- Company Overview: Extruder, Injection Molding PVC
- Developed and implemented a comprehensive preventive maintenance program for all production machinery.
- Ensured that safety regulations were followed by employees while performing maintenance tasks.
- Reviewed work orders, allocated resources, assigned tasks, and established priorities for completion of jobs.
- Supervised technicians on repair and installation of machines or systems according to manufacturer's specifications.
- Maintained records of repairs and parts inventory usage to optimize future planning efforts.
- Analyzed current procedures used by technicians during repairs and installations, making recommendations for improvements where applicable.
- Monitored inventory and ordered needed supplies to meet demand for repairs.
Education
Bachelor of Engineering - Mechanical Engineering
Mercubuana University
Meruya Jakarta Barat01-2008
Mechanical Engineering -
Polytechnic State of Semarang
01.2002
Skills
- Employee performance assessment&evaluation
- Budgeting and cost control
- Welding and fabrication
- Energy management
- Lockout and tagout procedures
- Operations Management
- Product Development
- Corporate Governance
- Project Management
- Data Analysis
- Performance Management
- Customer Relations
- Time management abilities
- Vendor Management
- Business Analysis
- Collaborate cross-functionally
- Revenue Growth
- Talent Acquisition
- Program Development
- Problem-solving aptitude
- Multitasking Abilities
- Adaptability
- Problem-solving abilities
- Reliability
- Performance reviewing
- Regulatory Compliance
- Crisis Management
- Professionalism
- Team building
- Innovation management
- Quality Control
- Communication Skills
- Employee Training
- Change Management
- Process Optimization
- Risk Management
- Plan projects
- Cost Reduction
- Profit and Loss Management
- Conflict Resolution
- Cross-functional team leadership
- TPM, Preventive Maintenance, FSPM, Predictive Maintenance,Corrective Maintenance
- PLC, Electric, Electronic, Pneumatic, Hydraulic, Inverter
- Travo, LVMDP, Cubicle, Capasitor bank
- Utility Compressor, Chiller, WWTP, Boiler, genset, Pump, Building
Websites
Certification
- PPPU Environment Training, 01/01/21, By Government
- Leadership Program, 01/01/18, By PT. Mattel Indonesia
- ISO 14001:2015 Internal Auditor, 01/01/15, By BSI
- Molding Excellent Program, 01/01/17, By Mattel Asia
- Neptune Assessment 2.0 for dairy, 01/01/14, By Danone France
- Delivering consistent quality in UHT, 01/01/13, By Tetra Pak
- Maintenance Extruder Mc Diploma, 01/01/04, By Rollepaal Netherland
Personal Information
Place of Birth: Klaten
Date of Birth: 04/01/80
Projectachievements
- PT.TNA, 02/2023 - 09/2024
Reduced downtime rate > 12% per year, increased MTBF > 12% per year, PM adherence > 98% per month
- PT. Changshin Indonesia, 01/2022 - 12/2023
Reduced Downtime rate >12%/year, Setup KPI dashboard, Fostered a culture of 5S as basic manufacturing
- PT.Mattel Indonesia, 06/2016 - 12/2021,
Enhanced TPM Implementation, Improved 5S to achieve score up to 4 of 5, Reduced NG parts up to 4% by Implementing Molding Excellent, Replaced electric motor to servomotor saving electric consumption 54%, Reduced 6 technician saving $15,800/year, Replaced 20 Injection Molding saving $270,000/year, Regular replacement screw barrel saving $410,000/year/10 unit
- PT.Drymix Indonesia, 12/2014 - 06/2016,
Installed new sand dryer machines, installed auto bag packer, and factory expansion design with consultant
- PT. Danone Dairy Indonesia, 01/2013 - 11/2014
Solved contamination problems, food safety, and preventive maintenance running well
Timeline
Maintenance Manager
PT.TNA
02.2023 - 09.2024
Sr. TPM Maintenance Manager
PT.Changshin Indonesia
01.2022 - 12.2022
Maintenance Manager
PT.Mattel Indonesia
06.2016 - 12.2021
Engineering & Maintenance Manager
PT.Drymix Indonesia
12.2014 - 06.2016
Assistant Preventive Maintenance Manager
PT.Danone Dairy Indonesia
01.2013 - 11.2014
Improvement Consultant
PT.Sentral Sarana Technology
05.2012 - 01.2013
Maintenance Supervisor
PT.Royalboard
10.2010 - 05.2012
Workshop & Engineering Manager
Rizky Jaya Persada
06.2007 - 07.2010
Maintenance Supervisor
PT.Wavin Duta Jaya
02.2004 - 05.2007
Bachelor of Engineering - Mechanical Engineering
Mercubuana University
Mechanical Engineering -
Polytechnic State of Semarang
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