PRASAD UNNIKRISHNAN

• As the in-charge of mechanical section in the main workshop of Saudi Arabian Railways, myself managed comprehensive maintenance activities including preventive, predictive, and corrective maintenance for a diverse range of railway equipment and vehicles:

· Tamping Machine (Make: Plasser & Theurer, Model: Duomatic 08-32 SH & 08-16 SH/3S ZW)

· Ballast Regulator (Model: SPZ200 & PBR 400)

· Sand Removal Machine (Make: Plasser & Theurer, Model: SRM 500)

· Track Inspection Car (Make: Geismar, Model: VMT 545 GR)

· Track Geometry Inspection Vehicle (Make: Plasser & Theurer, Model: EM120)

· Ultrasonic Testing Machine (Make: Speno International, Model: US2-3)

· Track Geometry Inspection Vehicle (Make: Matisa, Model: MPV 9S)

· Flash Butt Welding Machine (Make: Schlatter, Model: AMS 200)

• Led the mechanical team to ensure optimal performance, reliability, and compliance with operational and safety standards, contributing to uninterrupted railway operations across the network.
• As Workshop In-Charge and a collaborative team member, I successfully troubleshot and resolved a diverse and complex range of electrical, mechanical, hydraulic, and pneumatic faults across various track machines, ensuring minimal downtime and optimal performance.
• Ensured strict adherence to the Maximo maintenance system to meet client (Saudi Arabian Railway) requirements effectively, optimizing maintenance workflows and achieving operational excellence.
• Managed inventory and ensured the availability of optimum spares, oils, and lubricants for various machines and equipment to minimize breakdown time.
• Raised material requests for site activities and coordinated with vendors to ensure timely delivery of correct materials, maintaining optimal stock levels and supporting uninterrupted operations.
• Responsible for various maintenance activities of small railway equipment such as rail cutters, rail profile grinders, ERC clipping machines, and other portable equipment.

• In charge of complete maintenance operations (Preventive, Predictive, and Corrective) for following track machines:

· Tamping Machines: Plasser & Theurer – Unimat 08-32 4S & Duomatic 08-32 SH; China Tamping Machine – DC32

· Ballast Regulators: Knox Kershaw – KBR-925; China Regulator – SPZ200

· Sand Removal Machine: Plasser & Theurer – SRM 500

· Track Inspection Car: Geismar – VMT 545 GR

• Served as Workshop In-Charge, overseeing day-to-day maintenance, diagnostics, and performance optimization of all track machines.
• Troubleshot and resolved complex electrical, mechanical, hydraulic, and pneumatic faults, ensuring maximum equipment availability and minimal operational downtime.
• Ensured all maintenance and operational activities were executed safely and in full compliance with Saudi Arabian Railways safety and quality standards.
• Implemented and adhered to preventive maintenance schedules, optimizing equipment performance and extending service life.
• Responsible for various maintenance activities of small railway equipment such as rail cutters, rail profile grinders, ERC clipping machines, and other portable equipment.

• Oversaw erection and commissioning of Sleeper Plant (Make: RMS) with production capacity of 720 sleepers per day.

· Managed installation and operation of two EOT cranes for casting, demolding, and machine transfer operations.

· Supervised boiler plant used for steam curing and ensured safe and efficient operations.

• Led erection, commissioning, and maintenance of Batching Plant (Make: Schwing Stetter, Model: CP30), ensuring optimal functionality and continuous productivity.
• Maintained all key sleeper plant equipment — including casting machine, wire cutting machine, demolding machine, wire pulling machine, plate pull-up/push-down machine, pin push machine, and pre-stressing jacks — to consistently achieve 100% production targets
• Collaborated in design and fabrication of specialized equipment:

· Vibrating machine to reduce porosity and enhance sleeper quality.

· Gantry crane and self-propelled casting machine for turnout sleepers, improving efficiency and operational capability.

• Responsible for commissioning and maintenance (Preventive, Predictive, and Corrective) of:

· Tamping Machine: Plasser India – Unimat Junior 08-16/4

· Ballast Regulating Machine: Plasser India – PBR400

· Flash Butt Welding Machine: Progress Rail – H1000

· Utility Track Vehicle: Phooltas – 15MT

· Rail-cum-Road Vehicle: Phooltas – MAN Chassis (mounting Flash Butt Welding machine)

· Ballast Hopper Wagons: DAXI

• Ensured availability of spare parts, oils, and lubricants through effective inventory management, minimizing downtime and maintaining operational readiness.
• Raised and tracked material requests for workshop activities, coordinating with vendors to ensure timely delivery and maintain optimal stock levels.
• Finalized equipment specifications and selections for installation at Ghana Railway’s Locomotive and Wagon Maintenance Workshops and Railhead facilities, ensuring suitability, reliability, and adherence to technical requirements.

• Led erection and commissioning of New Track Construction Machine (Make: Harsco), ensuring smooth integration and reliable performance.
• Responsible for commissioning and maintenance (Preventive, Predictive, and Corrective) of:

· Tamping Machines: Harsco – Mark VI, Plasser India – Duomatic 08-32, Plasser & Theurer – Unimat 3S

· Dynamic Track Stabilizer Machine: Harsco – DTS

· Ballast Regulating Machine: Kershaw

· Flash Butt Welding Machines: Holland – H1000 and H1000 with Super Puller

· Utility Track Vehicle: Phooltas – 15MT

· Rail-cum-Road Vehicles: Navketan – Ashok Leyland and Bharat Benz chassis (mounting Flash Butt Welding machines)

• Supervised construction and setup of railway depot, which included:

· Erection and commissioning of gantries and roller lines for rail movement

· Establishment of 33 KV substation

· Setup of fully equipped workshop with precision tools and machinery

• Coordinated with planning and execution engineers to schedule and complete preventive maintenance activities without interrupting project progress.
• Ensured availability of spare parts, oils, lubricants, and consumables through effective inventory management, minimizing downtime.
• Raised and tracked material requests and coordinated with vendors to ensure timely delivery and maintain optimal stock levels.
• Minimised inventory loss for improved profit margins.