Pratheesh Kuttathu

Implemented best engineering practices in the factory to ensure plant budgeted technical reliability and availability. Lead planning & budgeting exercise to finalize department KPI related technical reliability. Lead WCM Pillar like IDG (EEM & EPM) to Initiate, Plan, Budget, Schedule and Execute plant developmental projects to keep the technology abreast . Collaborate with industry experts like GMT (Central Team in France) in analyzing plant loss deployment, devising business case, plan, schedule, budget & execute technology enhancement projects as part of IDG pillar. Lead electrical, automation and Utility team in detailed root cause analysis using problem solving tools like EWO, QK, SK and execute solution from these tools in coordination with production team. Structure, train and personally supervise planned maintenance system which includes, as minimum, use of condition monitoring, eradication of the causes of repetitive equipment failure, visual inspection and routine proactive replacement. Based on skill gap analysis of the team, plan training programs to develop staff, facilitate efficiency and improve performance. Key responsibilities:- Lead and successfully commissioned best market practice projects in Instrumentation & Process control like Scada Wincc Migration from V6.2 to V7.5, IN4.0 RM Production, Process & Recipe Module, Dryer Migration from MM440 to Sinamics G120 and Master drives to S120. Programming Knowledge in Wincc, Simatic Manager V5.6 and TIA portal V17. Lead and successfully executed process enhancing projects like Bottom Roller coating, feeder installations of Polymer, Retarder, Tartaric, PCE, Citric, Omadine and Hot & Cold water mixing for process improvement Lead and successfully commissioned "Gypsum recycling plant" as part of sustainability initiatives for internal recycling of gypsum boards to achieve Saint Gobain Group sustainability targets and cost reduction in procuring & transporting gypsum Knowledge in Chiller, Air compressor, Combustion systems, Firefighting and alarm systems.

Involved in shutdown activities, job allocations to technicians, modification jobs, calibrating and overhauling of all instruments. Troubleshooting Allen Bradley PLC and SCADA RS VIEW32. Servo Drives and Servo motors, (SEW and REXROTH), PMAC and Wimax programming. Siemens PLC, which controls the tube making machines (Asia) in production. Danfoss, Hitachi, Dietz and Sew Allen Bradley Variable Speed Drive. 840D and 802D PLC controller with Simo drive 611 which controls the milling machine. Different Sensors and transmitters. Thermo-hydrograph and Humidity devices used to monitor Temperature and Humidity OPTO 22. Ensuring availability of equipments, planning/executing Time & Condition based Preventive Maintenance. Monitoring MTTR & MTBF for improving machine productivity. Developing & executing best practices & standard operating procedures targeting at organizational excellence Maintaining ISO documents.

Accountable for Commissioning Siemens DC, AC and MC Drives (6RA70, 24, CUVC, MM4, CUMC) AB, ABB, Telemecanique, Danfoss, Lenz & Yashkava AC drives SSD DC & AC Drives (605, 615, 690, 650, 534, 590+ Series) Responsible for: Control Panel Design and Drawing, BOM preparation. Ladder logic development in Siemens S7 200, 300, 400 series PLCs Programming of AB series micrologix, SLC & Control Logics PLCs Profibus network Communication between Siemens PLC and Drives (CPU 313c 2DP) USS Communication between Siemens PLC and Drives (CPU 313c ptp) Programming & Calibration of Weighing Module (SIWAREX CS & U) Programming & Calibration of Temperature controller module (FM 355 & 455 PID Controller) Simolink, Peer to Peer Communication between drives Software Redundancy Between two PLC (CPU 315 2DP with IM 153-2) Screen development in Siemens WinCC SCADA, Protool Pro, Wincc Flexible HMI Communication between Siemens PLCs (FDL, GD, Int DP) Communication Between Two DP Networks using DP Couplers Commissioning of Siemens 3RW44 Soft Starter Micro PLC Logo soft comfort. Responsible for Analyzing & solving problems during commissioning. Daily review of maintenance activities, schedule calibration of instruments & preventive maintenance plans Planned for preventive maintenance in shut down, as well as attended the breakdown maintenance. Managed & utilized manpower at its best Issuing daily work orders for instrumentation maintenance. Preparation of failure analysis and reports