Electrical & Industrial Automation Engineer
Masafi Co.LLC
Total years of experience :11 years, 5 Months
Manufacturing & Production Unit - Pure & natural bottled drinking mineral water, fresh and
natural juices, tissue, flavored water and PET.
Summary of duties and responsibilities:
Production control/Electrical/Instrumentation/Industrial automation control system:
Maintaining daily and monthly KPI reading for line efficiency, mechanical efficiency, repair
and maintenance cost, cost/case and kW/case.
Knowledgeable in operation, troubleshooting and maintenance of Krones, Kosme, KHS,
Sidel, Robopac, Erco, oyster A+F, kettner, Side, Ozonia system, W+D, Haro Hofliger,
Zambelli, Husky, Netstal, Rp, and Engel injection machines.
Maintaining, testing and troubleshooting of electrical, electronics, field instruments,
mechanical and Automation control equipment’s such as PLC - siemens S7 200, 300,
400, 1200, Ge-Fanuc series 90-30, Omron, B&R automation devices, HMI, SCADA, safety
circuit devices and VFD drives(Danfoss, Sew eurodrive, Siemens, ABB, Fuji and Lenze).
Configuring and fault diagnosis of RTD, Sensor, flow meters, level switch, flow switch,
pressure switch, proximity sensor, safety devices, SSR and communication protocols such
as profibus, profinet, ethernet, modbus, CAN bus, Powerlink, RS232 and RS485.
Configuring and fault diagnosis of ASi bus system such as ASi master, ASi slave, Asi power
supply, ASi sensor, ASi cable, I/O module and field I/O devices.
Knowledgeable in repair and maintenance of various servo motors, encoders, AC & DC
motor, servo valve, pneumatic & Hydraulic valve and pump.
Maintaining and troubleshooting of blow molder, filler, labeler, shrink wrapper, palletizer,
case packer, stretch wrapper, checkmate, capper, handle applicator, bottling conveyor,
tissue folding & packaging and PET injection machines and auxiliary machine to ensure
their availability, safe and efficient operation production quality.
Responsible for the process and control settings for plant production machines.
Responsible to arranging the electrical, electronics, instrumentation and mechanical
spare parts for all machines with minimum inventory cost by planning their stock levels,
ordering them from suitable vendors and following with their purchasing cycle.
Responsible to implement the effective predictive, preventive and corrective
maintenance program recommended by equipment suppliers and carryout the
maintenance activities as per schedule.
Assist the technical team during maintenance, breakdown and project activities, perform
major repair of mechanical, electrical equipment’s and carryout technical analysis and
provide effective solution.
Monitoring and maintaining the records of machine efficiency after completing the
breakdown and preventive maintenance.
Providing process control support to the machine operators.
Implemented the 60, 000 and 20, 000 hours overhauling for 40, 000 and 18, 000 b/h
lines.
Develop and maintain the relations with quality, supply chain, planning and other cross
functional department on manufacturing concerns.
Planning and implement of daily and weekly production in all line as per schedule.
Maintaining the records of production and maintenance in day to day activities.
Planning work force and shift management activities.
Key Achievements:
Production target achieved last year - 94.01%
Improved:
Production output up to 16%
Mechanical efficiency from 80.20% to 85.33%.
Line efficiency from 69.5% to 76.36%.
Plant OEE from 52.89% to 55.48%.
Plant utilization from 56.29% to 57.33%.
Together with a 1.6 Year time served apprenticeship and vast instrumentation experience
in a hands on Water Treatment Plant and production platform environment.
Summary of duties and responsibilities:
Automation control system and Low current system:
Troubleshooting, controlling and monitoring of automation control equipment’s such as
PLC - siemens S7 200, 300, 400, 1200, keyence, johnson control DX9100v2, omron,
DCS, VFD drives and SCADA in water treatment Plant.
Programming and testing of PLC in ladder logic and Functional block diagram and data
handling functions in control logic processors.
Troubleshooting and selection of I/O modules according to site requirement and Support
various I/O devices connected to PLC’s (RTD, object & proximity sensor, flow meters,
level switch, flow switch, pressure switch, level transmitter, flow transmitter, pressure
transmitter, relays and safety relays).
Field service, erection and commissioning of industrial & building automation control
system by following the standard guideline and procedures.
Configuring and fault diagnosis of communication protocols such as profibus, profinet,
ethernet, modbus, CAN bus, Powerlink, RS232 and RS485.
Troubleshooting and controlling of mechanical and electrical equipments such as power
system, sump pump, safety system, lighting, HVAC, exhaust fan and ventilation
Installing, troubleshooting and monitoring of fire alarm system(Siemens fire finder XLS)
such as fire alarm panels, smoke detectors, heat detectors, manual call point, interface
addressable modules..
Review and finalization of control panel Design/Drawings.
Lead maintenance team in the troubleshooting of equipment issues.
Planned and executed of automation work activities, co-ordinate with clients and project
team, attended weekly progress meetings and co-ordinate with vendor work activities.
Vijayakumar CV Page 3 of 3
Electrical:
Erection and commissioning of power panel wiring & control panel wiring such as MDB,
SMDB, PLC control panels, UPS and other panel.
Knowledge to design starters such as DOL and star delta for AC, DC motors.
Testing and commissioning of MCC, MV, LV power system, lighting and switching control.
Installing and troubleshooting of electrical equipment’s such as circuit breakers,
contactor, relays, over load relays, voltage control regulator, motor and pump.
Inspection of approved electrical installations such as cable, cable tray, lighting, control
panel, primary and secondary power distribution, grounding system and electrical
equipment’s.
Good understanding of electrical drawing, planning of projects, erection and
commissioning of electrical installation.
Providing the entire electrical solution as per requirement and handling of electrical
Load as per requirement and supervision and coordination of electrical works.
Perform and assist all projects activities and co-ordinate with all concerned.
Perform routine inspection and documents result in accordance with approved material.
Ensure all installations are done as per specifications and made as per drawing.
Co-ordinate with clients and project team, attending weekly progress meetings and co-
ordinate with vendor work activities and prepare the project report on daily basis and
communicate with client on site for the clearance.
Ensure all the installations are done as per health, safety and environment plan
requirement.
Testing Repairing &
Desktop:
Chip level repairing of all kinds of laptop, desktop motherboards (L2 level) and RAM.
VI (Visual inspection) in all type of motherboards.
OQC (Outgoing Quality Check) chip level and SMD (surface mount device) chip level.
Desktop, Laptop, LCD monitor and projector assembling and disassembling.
Installing and configuring OS (Windows-98/xp/
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courses: Chennai. (