KAILAS — Senior Controls Engineer

Hardware design from scratch

Position: Engineering Manager and Technical Director- Managing Plant Automation Engineering Group. Previous Organization: DVS Technosoft Pvt Ltd — Pune. Period of Association: 1 st October 2015 to 31 st May 2017. Position: Technical Director- Managing Plant Automation Engineering Group. Responsibility in DVS Technosoft Inc: Working as Technical Director cum Engineering Manager: Leading & Managing Plant Automation Engineering Group. Contribute towards companies financial & technical growth. People Management (Locally & Globally) Project Management (Locally & Globally) Developing processes & best practices to deliver projects Within Budget, On Time with ZDD (Zero Delivery Defects). Project Planning & Tracking. Department/Project cash flow / budget management. Identify the critical issues in the project at every stages & provide counter measures to overcome these issues. Identify the business needs & opportunities to sustain locally & globally. Always try to provide latest plant automation & engineering techniques to our valuable customers. Arranging latest technical trainings & flawless project execution techniques sessions for the team. Coordinate between DVS USA & DVS India management team to plan & discuss about future projects, cash flow, company growth, strategic planning. Regular meetings with customers to have follow-up on current & future projects. Development of PLC & HMI standard templates for Electrical Engineering Department & PLC Software Department. Development of PLC & HMI standard templates for our valuable customers to reduce commissioning & debugging time, also to productivity & profitability. Responsibility in DVS Technosoft Pvt Ltd: Working as Technical Director: Leading & Managing Plant Automation Engineering Group. Contribute towards companies financial & technical growth. People Management. Project Management Developing processes & best practices to deliver projects Within Budget, On Time with ZDD (Zero Delivery Defects). Project Planning & Tracking. Identify the critical issues in the project at every stages & provide counter measures to overcome these issues. Identify the business needs & opportunities to sustain locally & globally. Always try to provide latest plant automation & engineering techniques to our valuable customers. Arranging latest technical trainings & flawless project execution techniques sessions for the team. Major projects Handled in DVS Technosoft Inc-Detroit: General Motors-USA & Mexico: Status: Ongoing. (Power Train) Responsible for Applying GCCS Safety PLC Program Standards for GM OEMs at USA, JAPAN & KOREA. O Responsible for flawless launches of the programs like CVT, CSS. Project Planning & Execution. • Chrysler (SHAP-RTO) Detroit: Status: Successfully Delivered. (Paint Shop RTO) Electrical Hardware System Design, PLC & HIM Software development as per FCA Standards. Responsible for flawless launches of the program. Project Planning & Execution. BASF Wyandotte: Status: Ongoing. (Ovens) O Electrical Hardware System Design, PLC & HIM Software development as per BASF Standards. O Responsible for flawless launches of the program. Project Planning & Execution. KASA (SHAP) Detroit: Status: Ongoing. (EMS Conveyor System) Commissioning start-up support. Responsible for flawless launches of the program. e Project Planning & Execution. DiFacto Detroit (Slinky Dog Dash Door): Status: Successfully Delivered. Electrical Hardware System Design, PLC & HIM Software development as per Disney Standards. O Responsible for flawless launches of the program. Project Planning & Execution. , KASA (GM) Arlington Texas: Status: Ongoing. (Conveyor System) Commissioning start-up support. Responsible for flawless launches of the program. e Project Planning & Execution. Anderson Process: Status: Ongoing. (EMS Conveyor System) Integration start-up support. Responsible for flawless launches of the program. Project Planning & Execution. EWAB Engineering (Germany): Status: Successfully Delivered. PLC & HIM Software development as per GM Standards. Responsible for flawless launches of the program. Project Planning & Execution. TranTek (Traverse City): Status: Successfully Delivered. O PLC & HIM Software development, Robot Interface as per GM Standards. Responsible for flawless launches of the program. Project Planning & Execution. Major projects Handled in DVS Technosoft Pvt Ltd-Pune: General Motors-USA & Mexico: Status: Ongoing. (Power Train) Responsible for Applying GCCS Safety PLC Program Standards for GM OEMs at USA, JAPAN & KOREA. Responsible for flawless launches of the programs like CVT, e Project Planning & Execution. Major projects Handled in Genix Automation Pvt Ltd-Pune: Tata Motors, PCBU (Car Plant) - Pune: Status: Ongoing. (Body Shop) Responsible for Controls Design of Xl Line. e Responsible for flawless launch. Project Planning & Execution. Tata Motors Ltd, Pantnagar, Uttarakhand: Status: Completed Successfully. (IE TCF) 250 UPD TCF Conveyor Line. Done Project Execution planning. Sorted out Device net network issue. Worked as Project Managen General Motors, Indonesia: Status: Completed Successfully. (Assembly Shop) Responsible for Controls Design. Responsible for flawless launch. Project Planning & Execution. Bajaj Auto Ltd, Waluj (Aurangabad): Status: Completed Successfully. (Body Shop) Responsible for Controls Design for 400 UPD Line. Project Budget Estimation. Finalizing Complete Required Bill of Material. Software Development; Q-Series PLC Logic using Mitsubishi GX Developer GOT 1000 HMI Screen Development using DT Designer Software. Responsible for flawless launch. Project Planning & Execution. Installation & Commissioning of; Complete System Mitsubishi Inverters on CC Link Network. Tata Motors Ltd, Pantnagar, Uttarakhand: Status: Completed Successfully. (Wheel Assembly Line) Responsible for Controls Design. Software Development. O Responsible for flawless launch. o Project Planning & Execution. Tata Motors Ltd, Dharwad: Status: Completed Successfully. (Wheel Assembly Line) Responsible for Controls Design. Software Development. e Responsible for flawless launch. e Project Planning & Execution. Major projects Handled during August 2010 — September 2011 with PCS, Pune: ADMA OPCO, Abu Dhabi (UAE): (Thermax India Ltd): (Oil Plant) Status: Competed Successfully. Developed & Modified PLC Program as process requirement. o Developed & Modified HMI as per process requirment. Commissiong activites & plant startup. Volks Wagen: (KUKA Robotics & Automation): (ED Conveyor Line) Status: Competed Successfully. Designed MCC panels as per customer's requirement. e Preparation of I/O list. Designed PLC panels as per customers process requirement. Developed PLC program (Siemens S7 Controller) as process requirment. o Development of HMI. Commissioning of ED Conveyor Line. GM Halol: (Expansion Of ELPO Oven System — Paint Shop) Status: Competed Successfully. Expansion of existing ELPO Oven system. Added 01 no. of oven & 03 zones. o Preparation of I/O list as per process requirement. Designed MCC panels which suits customer's requirement. o Designed PLC Panels as per process requirement. Modified & Developed PLC program as per process requirement (AB SLC500 Controller). Development of HMI. Commissioning. GM Halol: (ASU System — Paint Shop) Status: Competed Successfully. Preparation of I/O list as per process requirement. Designed MCC panels which suits customer's requirement. o Designed PLC Panels as per process requirement. Modified & Developed PLC program as per process requirement (AB Compact Logix Controller). Development of HMI. o Commissioning. GM Talegoan: (ED Conveyor Line — GA Shop) Status: Competed Successfully. Preparation of I/O list as per process requirement. Designed control wiring diagrams in EPLAN P8 as per GM Global Standards. Modified & Developed PLC program as per process requirement (AB Guard Logix Controller) & GM Global Standards Development of HMI. Commissioning of SEW Drives on Device net. Major projects Handled in General Motors Technical Centre-India: FSO Poland: (GM Poland): (60 JPH Line For NB, 31-1B, 5HB Model) Status: Competed Successfully. Controls Design For Body Shop Using E-Plan P8 for Main Line, Body Side Inner & Outer. o Development of Ladder Logic using GM developed standard software & Using RS Logix 5000 (Guard Logix) (Rockwell Software) o Generation and Validation of Software code in GM Global Architecture using RS Logix 5000 (Guard Logix), Integration For Main Line (Framing) 0 Development of HMI as per process requirement in GM Global Architecture using Siemens WinCC Flexible-2005 Software. Interface in between Robots (Fanuc), weld controllers, IS&S (Production Data) & Devices. Cactus: (GM Mexico): (30 JPH Line For NB, 5HB Model) Status: Competed Successfully. Controls Design for Body Shop Using E-Plan P8 for Main Line & Roof Line. Development of Ladder Logic using GM developed standard software & Using RS Logix 5000 (Guard Logix) (Rockwell Software) 0 Generation and Validation of Software code in GM Global Architecture using RS Logix 5000 (Guard Logix), Integration For Main Line (Framing) e Development of HMI as per process requirement in GM Global Architecture using Siemens WinCC Flexible-2005 Software. Interface in between Robots (Fanuc), weld controllers, IS&S (Production Data) & Devices. J300: (GM DEAWOO, South Korea): (60 JPH Line For NB, MPV7 Model) Status: Competed Successfully. Controls Design For Body Shop Using E-Plan P8 for Main Line, Body Side Outer & Rear Floor Line. Development of Ladder Logic using GM developed standard software & Using RS Logix 5000 (Guard Logix) (Rockwell Software) O Generation and Validation of Software code in GM Global Architecture using RS Logix 5000 (Guard Logix), Integration & Commissioning For Main Line (Framing) Development of HMI as per process requirement in GM Global Architecture using Siemens WinCC Flexible-2005 Software. Interface in between Robots (Fanuc), weld controllers, IS&S (Production Data) & Devices. M300: (GM DEAWOO, South Korea): (32 JPH Line For NB, MPV7 Model) Status: Competed Successfully. Worked as a Program Lead. Responsibility: . Understand the process for Body Shop and suggesting the Automation level to meet JPH for the Roof Line, Motor Compartment & Body Side Inner, outer & Marriage Line. Helping team members to learn & understand GM Global Architecture and implement the same in the project to meet the JPH. Making & verifying lists of ECS Panels, Controls component like Pneumatic manifolds, valves, switches, BKs, control cables, communication cables etc. by using GM Global Common Controls List to meet Project requirement by considering Human safety. Making & verifying lists of ECS Panels, Controls component like Pneumatic manifolds, valves, switches, BKs, control cables, communication cables etc. by using GM Global Common Controls List to meet Project requirement by considering Human safety. Controls Design for Body Shop Using E-Plan P8 for Motor Compartment & Roof Line. Development of Ladder Logic using GM developed standard software & Using RS Logix 5000 (Guard Logix) (Rockwell Software) Generation and Validation of Software code in GM Global Architecture using RS Logix 5000 (Guard Logix), Integration for Motor Compartment & Roof Line. Development of HMI as per process requirement in GM Global Architecture using Siemens WinCC Flexible-2007 Software. Interface in between Robots (Fanuc), weld controllers, IS&S (Production Data) & Devices. T300: (GM DEAWOO, South Korea): (60 JPH Line For NB, 3HB & 5HB Model) o Working as a Sr. Engineer. Responsibility: Understand the process for Body Shop and suggesting the Automation level to meet JPH for the Main Respot Line. Helping team members to leam & understand GM Global Architecture and implement the same in the project to meet the JPH. Working as mentor for other team members. Making & verifying lists of ECS Panels, Controls component like Pneumatic manifolds, valves, switches, BKs, control cables, communication cables etc. by using GM Global Common Controls List to meet Project requirement by considering Human safety. Controls Design For Body Shop Using E-Plan P8 for Main Respot Line. Development of Ladder Logic using GM developed standard software & Using RS Logix 5000 (Guard Logix) (Rockwell Software) Generation and Validation of Software code in GM Global Architecture using RS Logix 5000 (Guard Logix), Integration for Main Respot Line. Development of HMI as per process requirement in GM Global Architecture using Siemens WinCC Flexible-2007 Software. Interface in between Robots (Fanuc), weld controllers, IS&S (Production Data) & Devices. Major projects Handled in Rockwell Automation: A. Automotive: General Motors India Pvt Ltd (Commercial Vehicle Plant — Assembly And Body Shop); Halol (Vadodara, Gujarat)— Quality Alert System. Andon Board Systems. Erection and Commissioning of Andon System (Audio Visual Alarm System) For BIW Conveyor Line, Care Line, Final / Chassis Line, Trim Line. Erection and Commissioning of Panel View. Development of Ladder Programming and RS view and testing for the same for above lines. Lamp And PB Station Design, Manufacturing and Installation, Pull Cord Switch Mounting, Cable Tray Mounting, Cable Lying, Cable Termination etc. General Motors India Pvt Ltd (Commercial Vehicle Plant — Paint Shop); Halol (Vadodara, Gujarat)— • Pretreatment Area Process Control. e Commissioning of ELPO-OVEN Conveyor. • Development of HMI (Graphics) With Panel View Builder-32 Software and Development of Ladder Logic with RSLogix-500 Software For the same. Mines & Metals Jindal Steel & Power Ltd: (Tamnar, Chattisgarh) New Coal Washery. Ladder logic development and commissioning of the RMH Section, Deshaling Section, Washery Section for Coal Washery. Commissioning Of MCC, PLC Panels. SCADA screen development and testing of the same for above mentioned sections. BALCO, Korba (Chattisgarh) Fume Treatment Plant. Ladder logic development and commissioning of the Fume Treatment Plant. (FTP#OI, 02, 03, 04). SCADA screen development and testing of the Fume Treatment Plant. Ladder logic development and commissioning of the Fume Treatment Plant (FTP-I to 4). SCADA screen development and testing of the Fume Treatment Plant (FTP-I to 4). Drive Installation and Commissioning on Device Net Network. Consumer Durables Videocon Narmada Glass: (Bharuch, Gujarat) Glass Panel Finishing Plant. Ladder logic development and commissioning of the Cerium, WO-W6 and SAG Section. Testing and Commissioning Of MCC Panels, Operator Panel and PLC Panels. SCADA screen development and testing of the same for above mentioned sections for Panel View as well as Operator Console. Water Treatment 1. ITC Bhadrachalm: DM Water Plant. Conduction of FAT. Ladder logic development, SCADA screen development and testing of the same. Petrochemicals 1. Reliance Industries Ltd (Refinery), Jamnagar, Gujarat: Existing PLC Logic Segregation Conduction of FAT. Development and Testing Of SCADA for Panel View. Segregation, Development and Testing Of Ladder Programming. Supervision & Commissioning Of New Supplied PLC & MCC Panels Along With Inter panel Wiring. Ash Handling System 1. Gujarat Electricity Board (Thermal Power Station), Gandhinagar, Gujarat: Ash Handling System Conduction of FAT. Conduction of SAT. Development and Testing Of SCADA for Unit 01 To 05. Development, Testing and Commissioning Of Ladder Programming As Per Customer Process Requirement for Unit 01 To 05.

Pune. Position: Program Leader-(A/C: Cummins IDC: US, UK & Singapore Region Hardware & PLC Software Code Development Projects)

Pune. Position: Senior Manager-Projects

General Motors Technical Centre — India, Bangalore Position: Sr. Project Engineer (Body Shop Controls in CCRW Group)

Delhi Position: Project Engineer.