Ardent Learner

29 Years of Experience across Project Management, Maintenance Management, Quality Management & Production Management.

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ABOUT

ABOUT

ABOUT

ABOUT

ABOUT

A result oriented professional with Experience in Production/ Operation, Green Field & Brown Field Project, Equipment, Plant Maintenance, Industry 4.0 & Technical Training in 5 Majors: M/S TATA MOTORS LTD. (Automobile), Samtel Color Ltd. (Process Plant), CARRARO INDIA ( Automobile), Ashok Leyland Ltd. (Automobile) and ZF Group, it includes installation & Maintenance of Machine shop, Heat Treatment Plant, Utility Equipment and Operation.

Production

  • 1. CNC Machine - Production Setup
  • 2. Line Balancing - setup New Line and Meet Target
  • 3. Kaizen to improve Machine Cell Productivity

Project Management

  • 1. Capacity Calculation - Transformer, DG
  • 2. Plant Electrification - Cable Scheduling, Panel finalization
  • 3. Complete Machine Installation & Commissioning & Handover with company protocol

Equipment Maintenance

  • 1. Conventional & High-End CNC VMC, HMC – BFW, NIIGATA, TAL, Heller, Makino, Liebherr, Pfauter, Oerlikon, Gleason with Fanuc & Siemens Controller, Robotics and Pick & Place.
  • 2. Paint Booth and Paint Kitchen, Assembly and Overhead Conveyors
  • 3. Review MTBF, MTTR, CAPA, OEE, Failure Mode Analysis, Spares Cost, Team Training

Utility Equipment

  • 1. 22 & 66 KV Main Receiving station & Substation, 11 KVA & 500 VA DG Set, Compressor, Plant Lighting, Fire System, etc
  • 2. Crane & Hoist Maintenance - 40 Ton.
  • 3. Green Energy - Solar Projects

Heat Treatment Furnances Equipment

  • 1. Continuous Carburizing Furnace, Sealed quenched Furnace & all other accessories equipment, SCADA, DCS, Industry 4.0

Industry 4.0, Digitization & IIOT

  • 1. Digitization of Processes.
  • 2. ANDON on the assembly line, report generation, and analysis.
  • 3. LCA using Raspberry PI 4 & Implementation of SCADA,MIS on all the Process plants.

ORGANIZATIONAL EXPERIENCE

ORGANIZATIONAL EXPERIENCE

ORGANIZATIONAL EXPERIENCE

ORGANIZATIONAL EXPERIENCE

ORGANIZATIONAL EXPERIENCE

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TATA MOTORS, LUCKNOW

February 1993 - August 2004

Central Maintenance "Electronics Division"

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SAMTEL COLOR LIMITED, KOTA, RAJASTHAN

September 2004 - July 2005

Assistant Manager - Project

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GEAR WORLD(A CARRARO GROUP, ITALY), PUNE

August 2005 - July 2008

Deputy Manager

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M/S ASHOK LEYLAND LTD., PANTNAGAR, UTTARAKHAND

July 2008 - Jan 2010

Project Manager

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TATA MOTORS, JAMSHEDPUR

Jan 2010 - Feb 2022

Senior Manager, Plant Maintenance and Brown Field Projects

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ZF GROUP, JAMSHEDPUR

Feb 2022 - July 2022

AGM Plant Maintenance

TECHNICAL SKILLS

TECHNICAL SKILLS

TECHNICAL SKILLS

TECHNICAL SKILLS

TECHNICAL SKILLS

01. PLC Software

  • Step 5, TIA(Totally Integrated Automation) Portal, S7 Simatic Manager, Micro win for Siemens.
  • GX Developer for Mitsubishi.
  • RS Logix for Allen Bradley on Windows platform.

02. SCADA / MIS Software

  • RS View or Human Machine Interface for Allen Bradley on Windows NT(New Technology).
  • SCADA for Siemens - Win CC on Windows XP.
  • Wincc-Flex for HMI.

03. Machine Controls

  • CNC Controller Siemens – 840 D, 810D, 802D, Fanuc – 0i series, 160 I, 0i TD, 30i, 31i
  • Robotics and Pick & Place - Integration with Process plant and Machine Tools
  • PLC Allen Bradley SLC 500, Siemens – S7 300, S7 200, S7 1200
  • PLC Mitsubishi – Q-series, Fx-1n, Fx-2n, Fx- 3u
  • Robotics and Integration with Machine Tools.

AREA OF EXPERTISE

  • Inspiring the team in achieving the KPI through Technical and Motivational training involving Engineers, and contractors.
  • Resolving interpersonal issues & working towards a harmonious work environment.
  • Planning and conducting CSR activities on regular basis. Training to the Children in their Educational subjects helping them in their personal development by motivational Training. Developing infrastructure at Govt. school.

Anchoring on-site commissioning activities to ensure completion of project within the time & cost parameters and effective resource utilization to maximize the output.
Preparing SOP, MIS reports, manuals & work instructions for operations of Utility Equipment for the unit and performing layout finalization of commissioning activities.
Installation and Commissioning of the equipment as well as conducting tests & inspections to ensure operational effectiveness of plant & utilities.

  • Main assembly line and sub assembly line
  • Robotics and Pick & Place and Integration with the Machine Tools
  • Press Machines up to 40 T
  • Paint Conveyors, Paint Booth, Various washing machines
  • Electric Tightening tool – CP, Rexroth, Atlas Copco, Apex
  • Hypoid Gear Cutting & Testing Machine – Oerlikon & Gleason
  • Overhead Cranes and hoist – 40 Ton
  • Hobing Machine-Liebherr
  • Shaping Machine-Liebherr & Comur
  • Saving Machines-Hurth
  • Vertical Machining Centre-Tal.
  • Sealed Quench Furnace-Wesman Ipsen and 200,400 KG/HR, 50 KG /HR CGC Furnace
  • SCADA Page Design Data management
  • Induction Hardening Machine-Inductotherm.
  • Gear Teeth Grinding Machines-Samputensili, Reishauer.
  • Transformer, DG Set, AHU, Compressor, Sub-station, ETP & STP Plants

Troubleshooting/ analysis of the problem related to Controls, Pneumatics, Hydraulics and Mechanical system.
Root cause analysis execution of Preventive and Corrective action.
Spares management includes classification of spares into Critical & Non – Critical to reduce MTTR.

  • Main assembly line and sub assembly line.
  • Press Machines up to 40 T.
  • Paint Conveyors and Paint Booth, Various washing machines.
  • Electric Tightening tool – CP, Rexroth, Atlas Copco, Apex
  • Hypoid Gear Cutting & Testing Machine – Oerlikon & Gleason
  • Overhead Cranes and hoist – 40 Ton
  • Hobing Machine-Liebherr.
  • Shaping Machine-Liebherr & Comur./li>
  • Saving Machines-Hurth. SICMAT
  • Vertical Machining Centre-TAL,BFW, UNISIGN, HELLER
  • Sealed Quench Furnace-Wesman Ipsen, 200 KG/HR, 50 KG /HR CGC Furnace
  • Induction Hrdening Machine-Inductotherm. IEI
  • Transformer, DG Set, FDV, Compressor, Sub-station, ETP & STP Plants.
  • SCADA & Industry 4.0
  • Executed cost-saving techniques/ measures and modifications to achieve substantial reduction in O&M expenditures and work within the budget.
  • Executing Kaizen Events.
  • Preparation for a different level of world Class Quality Levels.
  • Leading IATF 16949 Implementation
  • ISO 9000 Internal Auditor
  • Member of Steering Committee TS 16949
  • Line Balancing – Lean Manufacturing
  • MOST Analysis to determine Cycle Time
  • Executed Kizen Projects to increase Productivity
  • Setup New Machine Cell and Startup
  • Setup New Assembly Line and successful Startup.