Currently I have experience in projects from Level 0 to Level 3 in manufacturing. Worked for clients like Jaguar Land Rover for their performance management tool implementation.
Also have done consulting projects in Automotive industry on Performance Management, Lineside replenishment, Inventory Management, Documenting the process flows for entire Automotive process right from Order generation to Dispatch of a car etc.
9 years of rich experience in Industrial Automation and MES with domain expertise in Automotive, Oil and gas, Food, Tank-farm Automation. Expert in understanding manufacturing processes in various domains keeping MES functionalities in mind.
Expert in entire range of Wonderware products like System Platform 3.1, HMI Reports 3.4, InTouch 10.1 and 9.5, Wonderware Historian, recipe management and Activefactory Reporting. Proficient in range of Rockwell Performance and visibility products like FTMetrics, FTSchedular, FTHistorian and FTView. Proficient on Cimplicity 8.2. Experience on other software like RSLogix 5000, various OPC Data Access Servers and Activex. Possess excellent analysis, designing and project development skills.
Preparing project schedules as per clients’ requirements
Effective resource planning for optimising man & machine utilisation, reducing wastes for enhancing productivity and profitability
MES and Industrial Automation
Client interaction for requirement gathering, system study & analysis.
Drafting reply to RFPs, functional requirements for MES, and Industrial Automation
Understanding the technical & functional specifications.
Design, development, testing, troubleshooting and debugging of the applications.
Managing smooth implementation and testing of the application at client location.
Providing post-implementation, enhancement and maintenance support to client for application.
From July’12 till date
With Tata Consultancy Services, as Consultant, MES
Functional understanding of automotive domain and overall IT landscape of one of the most prestigious car making company in the world.
1. Drafting of entire Car making processes right from Order generation to Customer acceptance line.
2. Drafting of process flows and various application touch points in BIW, Paint, Body storage and Trim and final assembly line.
3. Understanding and requirement gathering of various parts of car making like
Line side material replenishment, Performance management, Maintenance management, Broadcast to suppliers, JIT parts sequencing, subassembly sequencing, Scheduling in Body shop, Sequencing the cars from Painted body storage, Car tracking, Genealogy capture (Traceability), Quality testing etc.
4. Fit gap analysis of applications in shop floor. These applications are going to be rolled out globally for all customer plants.
Worked on Fit gap analysis (Functional as well as from system perspective) for replacing a legacy performance management system with new one. Also worked on Design, development and commissioning of Performance enhancement application for Body shop using Cimplicity 8.2 and SQL server database. My role was Cimplicity Develoment and integration with ANDONs, shop floor PLCs and database.
MES Functionality: OEE management, Maintenance Management using ANDON boards, Extensive Reporting
Front End: Cimplicity 8.2
Database: SQL server 2008
Reporting: SQL server reporting services
Integration Services: RSLinx OPC server
Reply to RFP for FRS Gathering and MES implementation in a Truck Manufacturing company in Japan.
Functional understanding and requirements gathering of Engine manufacturing for MES mapping with respect to following points:
1. Order generation and scheduling of work orders in MES or SAP
2. Integration with SAP for work order sequencing
3. Defining Cost centers and Quality gates (WIP and end of line)
4. Genealogy capturing
5. Part Kitting, subassembly manufacturing and scheduling, bulk picking (Line side replenishment)
6. Defect posting, Part substitution, short build, Lift on, reentry etc.
7. PLC to MES handshaking.
From Sept ’10 to May’12
With Larsenbro Infotech, as Associate Consultant, MES
Preparing case studies and presentations for specific industry using various Rockwell products like FTMetrics, FTSchedular, FTHistorian and FTView.
Prepared RFP document for Dubai Refreshment Company for their bottling plant in UAE.
RFP Documentation included
• Requirements Gathering
• As-Is Understanding
• Detailed Functional Requirements
• Mapping MES Functionalities as per MESA model
Development and dispatch of Work Packages, Work Plans and Reports for client in US using Solumina MES package. Also done a POC for one of esteemed clients in Aviation industry in US, where integration of SAP and Solumina is done using SAP Netweaver PI and ActiveMQ as JMS provider.
MES Package: Solumina G7R4
Front End: Solumina Thin Client
Database: Oracle 11G R1
Reporting: Rave Tool
Integration Services: Solumina BIS, SAP NetWeaver PI
From Dec ’09 to Sept ’10
With KLG Systel Ltd., as Application Engineer
Project Designing, Development and commissioning for 3M Pune, in InTouch 10.1 having Recipe implementation and in depth SQL reporting.
Project Development and commissioning for Axiomtek InTouch CE 10.1 displays at Apollo Tyres, Chennai, where displays are communicating with transmitters on wireless communication.
Developed and commissioned Wonderware application based on System platform 3.1 in Nestle plant at Bicholim, Goa. Application included one Development (GR) node and view nodes located in different parts of factory like boiler utility, different process lines etc. Data was continuously logged into Wonderware Historian and ActiveFactory reports and charts were designed keeping Operation and Maintenance department in consideration
Worked on System Platform 3.1 for Power project at Abudhabi Takreer plant.
Developed HMI Reports 3.4 application for JSW steel plant at Vasind.
April’09 to Dec’09
With Lasons Technologies as Lead Engineer, Automation Software
Designing and Commissioning FTView SCADA and Compact Logix PLC for company’s Plant at Taloja MIDC. A Pharma company with Niacin and Niacin Amide as their main product. A Batch Process.
Designing and developing applications in VB for them which fetch data from SCADA through RSLinx (Communication on NetDDE and Remote OPC).
Have also designed Automatic report generation tool in Excel for their reporting and analysis of production daily, batch wise and month wise with flexibility from operation point of view.
Dec’06 to Jun’07
With Sarla Technologies, as Senior Projects Engineer
Application Development in InTouch for the projects in Food Industry
Client: Invensys, Denmark
Duration: Dec’06 to June’07
Role: Senior Projects Engineer
Developing standards along with Invensys for Application Development in InTouch for their projects in Food Industry at their location in Silkeborg, Denmark.
Facilitating support to the colleagues in understanding the standards and developing application accordingly. Interfacing with the client for analysing the requirement for application development.
Delivering the designed applications to the client after checking it from various perspectives.
Spearheading a team of 6 engineers at Sarla Technologies for executing the projects.
Jun’05 to Oct’06
With Inconsys Ltd., working on Wonderware In Touch SCADA Lead Systems Engineer
Client: Qatar Petroleum
Environment: SCADA: Wonderware InTouch 8.0
Database: SQL server through Industrial SQL server.
IO and DA Servers: MBENET for Modicon Quantum PLC, OPCLink as a link between HIMA OPC Server and InTouch, DASABTCP for SLC5/02 AB PLC
OPC Server: HIMA OPC Server 3.0
PLC involved: Modicon Quantum, HIMA, AB SLC5/02 and PLC5
Played a major role in the Crude Oil and Naphtha Loading.
Crude and Naphtha is stored into storage tanks located at about 10 km from location of loading arms. So there are two distinguished regions in this project which communicate through Fibre Optic cables, viz: Multi Product Berth (MPB) i.e. loading arms area and Storage Tank Farm.
The process part is controlled by Modicon Quantum PLCs and separate Emergency Shutdown system and Fire and Gas system is controlled using HIMA PLCs.
Metering of Crude and Naptha is done by ALDERLY fze.
Wonderware InTouch SCADA is used as a Control and Monitoring application for the whole project.
There is 1 Engineering Workstation and 7 operating workstations in different regions. Each operating workstation is linked with engineering workstation through NAD architecture.
All the Wonderware were connected to PLCs like HIMA (communicating with HIMA OPC server through OPCLink), Modicon Quantum (Through MBENET), AB (Through DASABTCP) and also to systems like Metering by Alderly, Substation (Alstom Relays directly connected to SCADA).
Entire Communication Network was on Ethernet with Dual redundancy at PLC as well as HMI side.
There are two centralized redundant I/O servers from which all InTouch Applications fetch the data. Analog data is logged through Industrial SQL Server and discrete alarms/events are logged into SQL server through Wonderware alarm DB Logger utility.
Jul’04 to May’05
With M/s United Engineers,Dombivili
Pump Energy and Efficiency Monitoring Software (Pump Enhance) in Visual Basic
Environment: PLC Software: RSLogix 500,
SCADA: InTouch 9.0., Visual Basic 6.0 as front end, SQL Server,
Reporting Software: Crystal Report 8.0, OPC Server: KEPWare KepserverEx 4.0, Activex: Software Toolbox OPC Data Control.
Wonderware InTouch 9.0 is integrated in this project as HMI to operator. The calculation of flow, Efficiency and losses of the Pump set is made in Visual Basic.
1. Exposure to Car Manufacturing processes like Vehicle Scheduling and Sequencing, functioning of BIW, Paint and Trim and Final Assembly line, Inventory replenishments, Supplier Broadcasting, Sequencing of subassemblies, Knockdown processes, and interaction with PLCs.
2. Exposure to Lean Manufacturing: JIT, JIDOKA, PokaYoke, Reducing Waste.
3. Exposure to Engine manufacturing processes.
4. Exposure to various domains like Automotive, Oil and Gas, Tankfarm Automation, Beverage industry, Food industry, Pharma industry
B.E (Instrumentation Engineering) from Konkan Gyanpeeth College of Engineering, Mumbai University in 2003 with 68.21%.
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