Satyashil Salve

  • Muscat, Sultanate Of Oman

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

Work History

Work History

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 2009 - Jan 2015

Assistant Manager Engineering

Reem Batteries & Power Appliances Co. SAOC

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


  • 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 2007 - Jan 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

  • 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 2006 - Jul 2007

Member Maintenance - Electrical Engineering

TATA Autocomp Systems Ltd. Pune

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

  • 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


  • 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 2003 - Jul 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


  • 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 2001 - Apr 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


Jul 1996 - Jun 2000

B.E. Electrical 

Govt. College of Engineering, Karad, Maharashtra, INDIA



Siemens PLC - Series 200, Series 300, Simotion, WinCC

Programming, trobleshooting

Allen Bradley - SLC500, SLC5000, Factory Talk

Programming & Troubleshooting



ISO 14000 & 18000 - Internal Auditor

Certified Internal Auditor from Velosi