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Satyashil Salve

Project Engineering and Plant Maintenance Expert with over 14 years of experience

Work experience

Key Skills

  • Project PLANNING, COSTING & CONTROL for the timely execution of projects
  • PLCMaintenance: Siemens S7 200 & 300 series, AB-SLC 500 & Micrologix 1200,  GE Fanuc, Mitsubishi
  • PLC Programming: Microwin4.22, SimaticS7 Manager, WinCC Flexible Compact,    RSLogix500, RSLogix5000, Simotion SCOUT for Servo drive
  • Variable Frequency Drives and Soft Starters ( Allen Bradley, Yaskava, Danfoss,    Mitsubishi, Rhymbus, Delta)
  • Servo Drives – Simotion D425, Indramat, Bechoff, Yaskava
  • Condition Monitoring : Thermography, Vibration Analysis 
  • CMMS, SAP, MSProjects, MIS
  • Certified Internal Auditor for ISO 14000 & 18000
  • Exposure to ISO 9001:2008
Jan 2009Jan 2015

Assistant Manager Engineering

Reem Batteries & Power Appliances Co. SAOC

Company : Company Manufacturing Dry charged and Maintenance Free Automotive batteries with 85% export

Responsibilities:

  • Retrofitting of the old machines to adopt new technology
  • Projects planning, Control, Budgeting and Execution
  • In-house PLC programming using Siemens S7 200 / 30 series
  • Design and development of the SPMs in-house along with manufacturing
  • Continuous Process improvement using latest technology
  • To adopt energy saving techniques
  • Maintenance of Plant machines, SPMs, Utilities, Fire fighting systems
  • Budgeting and Inventory control
  • Complete project documentation for the system up gradation
  • Maintenance of 8 MVA Substations
  • Maintenance of Environment control Equipments
  • Training of subordinates for better competency
  • MIS reports preparation
  • Certified Internal Auditor for ISO 14000 & 18000: 2008

 Achievements :

  • Retrofitting of machines using Siemens S7 series PLC to adopt latest technology - Savings of OMR 20000/-
  • Low Cost, In house Line automation to reduce machine cycle time, manpower and improve quality
  • Performed in-house Energy Audits implemented the techniques to reduce consumption which saved about OMR 12000 p.a.
  • Repair and Maintenance cost reduction by 1.5% for the year 2014
  • Effectively implemented the Predictive maintenance program for plant machinery this resulted in reducing the breakdown by 0.6%
  • Installation of Soft Starters for the high capacity Bag house motors to avoid the failure of motors and Power Saving
  • Successfully completed the PLC Training Program for subordinates
  • Successfully Handled the Installation and commissioning of new machines
Jul 2007Jan 2009

Assistant Manager - Projects & Maintenance

Cooper Standard Automative India Pvt. Ltd, Pune

Company: US MNC Manufacturing Fluid handling systems for TML, GM, Ford & M&M
Responsibilities:

  • Costing, Budgeting of the project activity
  • Machinery finalization and selection with all comparisons
  •  Liaisioning with Govt. Depts. MSEB, PCB, Factories Inspector, Grampanchayat etc.
  •  Application for Power and power release from MSEB
  • Installation and commissioning of Switchyard (22kV/.433Kv), LT Room, DG, Compressor,  boiler
  • Designing of plant internal electrical layout
  • Installation commissioning of Machines - CNCs, SPMs, Steam Forming Machines, Spot welding      machines, Ind. Brazing machines, PA Tube cutting machines, Steel tube cutting  machines etc.
  • Design and development of Semi Automatic SPM machines for special operations
  • Implementation of TS16949
  • Training of production persons for machine operation.
  • Preparation of Preventive, Predictive maintenance schedules Indigenization of Spare parts
  • Preparation of MIS reports, keeping maintenance cost below 0.07% of annual sales value
  • Breakdown reduction below 1.2%
  • Implementation of Safety systems and training to all employees,
  • »Implementation of 5S



Aug 2006Jul 2007

Member Maintenance - Electrical Engineering

TATA Autocomp Systems Ltd. Pune

Company: Manufacturing the Car Interiors & Exterior for Tata Motors, Fiat, GM & Toyota
Responsibilities:

  • Breakdown Maintenance, Preventive Maintenance and Predictive Maintenance
  • Installation and Commissioning of Machines
  • Machines : Injection Molding Machines - from 60T to 2700T Battenfeld, Husky,  Mitsubishi, Engel and    L&T make, with PLC of make Schleicher, Mitsubishi and Messung,  Paint Shop for Bumper and Door Trim painting
  • U/S Welding Machines, Mold Temp Controllers, Loaders
  • Pick and Place Robots : Programming and Troubleshooting of Battenfeld, Engel and Apex  make
  • Woodstock Punching Press Machine, Paint shop Maintenance
  • Modification and energy saving implementation for the machines
  • Predictive Maintenance - Vibration Analysis, Oil Analysis, Thermography
  • Substation Equipments : 22kV/415V, 2MVA 2 Nos. with OLTC, RTTC, VCB, ACBs,  Capacitor Banks 600KVAR 2 Nos with APFC Panels, LT Distribution,
  • Utilities : DG Sets 1250 KVA 2 Nos. with AMF panel, Chiller, Compressor, Cranes 10T,  20T, 40T, Fork lifts
  • Identification of Critical Spares and keeping the minimum inventory
  • Budget allocation
  • MIS Report Preparation, Calculations of MTTR & MTBF and Tracking the B/Ds and Why  Why analysis, attending the Operations Review Meetings
  • Liasioning with MSEB
  • Updation of Standard Work Instructions for Preventive Maintenance
  • Technical Training for Technicians

Achievements:

  • Energy saving Approach : Motion sensor for Public Places which saved about 30% of annual consumption,
  • Photosensor for plant and street lighting which saved about 50K per annum,
  • Drives for Compressor and Drive for the Wood Stock Hydraulic Motor.
  • Drives for Paintshop Oven Blowers - energy saving of 12%
  • Drives for Water Circulation pumps in Paint shop - Energy saving of 15 %
  • Retrofitting the old PLC by new PLC for Injection Molding Machine
  • QMC installation for old Mitsubishi Injection Molding Machine with Messung PLC
  • Indigenization of spares which saved about 20% on the annual cost.
  • Inhouse development of PCB level repair which saved about 24% of the total repair cost.
  • Indigenization of US welding machines which saved about Rs. 15 lakh / annum
  • Design and Development of two SPMs for Bumper cutting and punching machines.


Apr 2003Jul 2006

Maintenance Engineer - Electrical

Effem India Pvt. Ltd, Hyderabad

Company: Owned by MARS INC. USA - FMCG Manufacturing Pet Food in India.
Responsibilities :
As a Project Engineer :

  • Erection Commissioning of total plant machinery includes: Milling m/c, Extruder, Dryer  & Cooler,  Packing Machines, Injection Molding machine, Various Conveyors
  • Erection Commissioning of 33KV/415V, 2 MVA Substation with LT Distribution.
  • Liaisoning with Govt Depts.
  • Installation of Capacitor Banks and APFC.
  • Design Erection and Commissioning of PCC & MCC.
  • Co ordination at site during Project erection & testing.
  • Design and Commissioning of Control Panels of all m/c
  • Preparation of SLD and all wiring diagrams.
  • Erections commissioning of Utilities like Compressor, Chiller, Water Pur. System,

As a Maintenance Engineer:

  • Preventive and B/D Maintenance - Electrical and Instrumentation
  • Preparation and Updating the PM Schedules
  • B/D Reports and analysis.
  • Predictive : Condition Monitoring : Thermography and Vibration Analysis
  • Implementation of Safety Procedures and providing additional special interlocks
  • Preparation and updating of History Cards
  • Analysis of Electricity Consumption
  • Indigenisation of Spare Parts
  • Negotiations with subcontractors and suppliers
  • Material Handling Equipment.
  • MIS Reports Preparation
  • Maintenance of Fire fighting equipments in the plant

Achievements:

  • Installation of individual kWh meters for each m/c which gave good result to get actual kWh/ton of production and also able to give the projected figures for consumption.
  • Energy Conservation Approach:
  • Achieved about 15% Electricity saving by implementing energy saving techniques
  • Obtained 12% saving in lighting consumption
  • Modification in PLC ladder logic to give higher output of 2000 kg/hr for mill.
  • Modification on Packing m/c which resulted in reducing down time from 8% to 0.5%
  • Installation commissioning of Steam Automation system which gave better control on  the temperature profile of spray preparation
  • Positive approach for modifying the systems go get zero B/D time, better output and  efficiency


Sep 2001Apr 2003

Maintenance Engineer

Whirlpool of India Ltd. Pune

Company manufacturing: Refrigerators, Washing Machines, Air Conditioners
Responsibilities :

  • Break Down Maintenance, Preventive Maintenance
  • Machines handled: Hydraulically Operated Press from Taiwan, Paint Line from Eisenman  USA, and Cabinet Fabrication & Door Fabrication machine from SCOTT, NewZealand,  Door and Cabinet Foaming machines from Canon, Leak Detectors like Ecotec500,  HLD4000, HV Testers.
  • Maintenance for Chiller , Compressors, AHU, 1500 KVA and 160 KVA DG Set, EOT Crane 10 Ton
  • Maintenance of 132 KV and 11 KV Switchyards
  • Pick and Place robots
  • Maintenance of Various Mesh Conveyors for Paint Line, Belt Conveyors

Achievements :

  • Increased the Production rate by reducing the Pouring time by 17 sec for a cycle by introducing the reverse pouring
  • Awarded by Stretch Award for successfully completion of the installation project of CAL   and RUN TEST Laboratories which check the refrigerators on the line

Education

Jul 1996Jun 2000

B.E. Electrical 

Govt. College of Engineering, Karad, Maharashtra, INDIA

Skills

Siemens PLC - Series 200, Series 300, Simotion, WinCC
Programming, trobleshooting
Allen Bradley - SLC500, SLC5000, Factory Talk
Programming & Troubleshooting
AutoCad
MIS & CMMS
ISO 14000 & 18000 - Internal Auditor
Certified Internal Auditor from Velosi