Allen Bradley PLC MicroLogix, SLC, CompactLogix, FTView, Kepware
Nitin Fegade
Founder Director-Industrial Automation Business
Thane,MH
Summary
- Proactive Automation Engineer possessing in-depth knowledge of various programming languages and best practices for development. Solutions-based collaborator well-versed in testing and simulating automated machinery, developing and implementing automated testing methodologies and supervising testing activities. Offering 24 years of experience creating and applying technology to monitor and control production.
- Experienced Automation Expert with over 24 years of experience in construction material business, steel, glass, pharmaceutical, Airport, Metro rail project, data centres, home automation etc. . Excellent reputation for resolving problems and improving customer satisfaction. History of streamlining operations, increasing revenue and reducing costs to maximize business profits. Decisive and strategic leader with demonstrated track record of success.
- Agile leader of systems automation with team-oriented mindset, collaborating with staff from all departments to streamline productivity with technology-based solutions. Flexible producer of effective code tailored to organizational needs. Authority on technical process automation with strong base of knowledge of evolving solutions to uncharted problems.
- To seek and maintain full-time position that offers professional challenges utilizing interpersonal skills, excellent time management and problem-solving skills.
Overview
19
19
years of professional experience
4
4
years of post-secondary education
14
14
Certifications
Work History
Founding Director-Industrial Automation Company
Bhanuleelai Technologies OPC Pvt. Ltd.
Thane-Mumbai
07.2022 - Current
- Training & Development, Engineering Controls, Industrial Automation, PLC/SCADA/DCS/SERVO/Robotics, mentored over 25-30 techies per month to make them future ready to the world of Industrial automation & digital transformation.
- Spearheaded innovative approaches to resource allocation and strategic planning. Actively participation in project design review, procurement, manufacturing, testing & commissioning.
- Communicated regularly with customers concerning data exchange and technology integration.
- Formed strategic partnerships and connected with potential clients to drive business development.
- Reviewed and assessed architecture design, implementation, testing and deployment needs to identify project requirements and costs.
- Leveraged professional networks and industry knowledge to strengthen client relationships.
- Led and assisted technical upgrade projects for clients by working and coordinating with consultants and developers for integrations.
- Proved successful working within tight deadlines and fast-paced atmosphere.
- Created spreadsheets using Microsoft Excel for daily, weekly and monthly reporting.
- Established departmental performance goals and provided feedback for underperforming areas.
- Monitored expenditures to mitigate risk of overages.
- Decide staffing requirements, and interview, hire and train new employees, or oversee those personnel processes
- Analyzed business needs while soliciting customer feedback for process improvements.
- Generated process models illustrating automation engineering progress, specifications and details.
- Troubleshoot, fixed and improved electrical controls.
- Tested, automated and whitelisted software to be used in secure environments.
- Collaborated with systems engineers and customers to determine machine requirements and develop specifications for user interface, machine functions and quality control to deliver reliable automation systems.
- Performed gap analysis procedures and detailed data reviews to optimize implementation.
- Supported facility and process equipment engineering and design, integration and validation.
Manager-Production Operations
Saint Gobain Gyproc India Limited
Mumbai
06.2008 - 07.2016
- Maximized performance by monitoring daily activities and mentoring team members.
- Accomplished multiple tasks within established timeframes.
- Evaluated operational systems and recommended design modifications to eliminate causes of malfunctions or changes in system requirements.
- Built and deployed programs to maintain database organization and integrity.
- Expanded cross-functional organizational capacity by collaborating across departments on priorities, functions and common goals.
- Planned or developed applications or modifications for electronic properties used in components, products or systems to improve technical performance.
- Evaluated electrical installations and systems to isolate faults and implement corrective actions.
- Performed maintenance procedures and repairs on existing electrical products and systems.
- Identified specific cables, fuses and circuit breakers required for assigned installations.
- Prepared technical documentation for operation, troubleshooting and maintenance of industrial systems.
- Reduced electrical construction hazards with upgraded safety policies and stringent enforcement.
- Monitored manufacturing operations of electrical devices for compliance with safety protocols.
- Calibrated and repaired existing systems to maintain functionality.
- Inspected and performed validation testing for designed systems and third-party installations.
- Validated product and subsystem performance through simulation and laboratory testing.
- Established best practices and innovative solutions to enhance production rates and output quality.
- Kept detailed records of daily progress to identify and correct areas needing improvement.
- Implemented team-wide safety program, automated the operations with highly sophisticated controls & interlocks to improve on plant safety, environments & health.
- Controlled costs and optimized spending via restructuring of budgets for labor, capital assets, inventory purchasing and technology upgrades.
- Resolved staff member conflicts, actively listening to concerns and finding appropriate middle ground.
- Supported Engineering and Maintenance departments with training and technical support.
- Applied customer feedback to develop process improvements and support long-term business needs.
- Evaluated employees' strengths and assigned tasks based upon experience and training.
- Cross-trained existing employees to maximize team agility and performance.
- Supported facility and process equipment engineering and design, integration and validation.
- Delivered feedback to decision-makers regarding employee performance and training needs.
- Recruited and hired top performers to add talent and value to department.
- Supervised labor costs and departmental expenses to remain in line with budget.
- Reduced process bottlenecks by training and coaching employees on practices, procedures and performance strategies.
- Utilized comprehensive understanding of Siemens, Allen Bradley, ABB, Mitsubishi, Delta Ladder Logic to produce code to revolutionize automation.
- Prepared annual budgets with controls to prevent overages.
Head-Electrical & Instrumentation
Christ Nishotech Water Systems India Pvt. Ltd.
Navi Mumbai
03.2007 - 06.2008
- Preparation & checks of documentations like functional logic, hardware design specification, and software design specification, and PLC Validation document, panel inspection protocol.
- Actively involved in software development & testing of PLC & SCADA applications to all the system requirements, flow down, and verification, PLC validation as per the GAMP requirements.
- Control Panel Design, Wiring, Programming, Testing (FAT), On-site Project execution. Collaborated with team members to achieve target results.
- Identified issues, analyzed information and provided solutions to problems.
- Worked with customers to understand needs and provide excellent service.
- Exceeded goals through effective task prioritization and great work ethic.
- Developed and implemented performance improvement strategies and plans to promote continuous improvement.
- Actively involved in CSV (computer system validation), PLC validation: - Risk assessment, change control, URS, DQ, IQ, OQ, PQ customers protocols.
Sr. Executive-Engineering
Bharat Serums & Vaccines Limited
Ambernath
02.2004 - 03.2007
- Carried out day-to-day duties accurately and efficiently. Maintenance of all existing sites, BMS, PLC & SCADA systems.
- Operation & maintenance of all utility equipment like boilers, air compressor, chiller, Gases
- Documentation management: like scheduling, SOP's, preventive maintenance (check lists, History cards), calibrations, daily operation logs, BMS data & trends,
- Participated in team-building activities to enhance working relationships. Audit preparation & presentation
- Equipment Validations as per protocols, data management. Resolved problems, improved operations and provided exceptional service.
- Participated in continuous improvement by generating suggestions, engaging in problem-solving activities to support teamwork.
- Worked within applicable standards, policies and regulatory guidelines to promote safe working environment.
- CSV (computer system validation), PLC validation: -preparation of Master validation plan, Risk assessment, URS, DQ, IQ, OQ, PQ.
- Led projects and analyzed data to identify opportunities for improvement.
- Managed team of employees, overseeing hiring, training and professional growth of employees.
Lead Engineer-Automation
Metalchem Industries
Mumbai
04.1998 - 02.2004
- Development of PLC & SCADA applications to all system requirements, flow down, and verification, PLC validation as per GAMP requirements
- Adhered to timelines to meet quality assurance targets. Preparation of Electrical & Instrumentation BOQ, instrument schedule, cable schedule, instrument index etc. & status of the work.
- Control Panel Design, Wiring, Programming, Testing (FAT), On-site Project execution.
- Coordinated with systems partners to finalize designs and confirm requirements.
- Tested, evaluated and fixed safety systems. site management & co-ordination with project team.
- Developed positive working relationships with stakeholders to effectively coordinate work activities.
- Wrote, reviewed and edited technical document in accordance with template requirements.
- Trained and mentored competent and flexible workforce to meet project needs and promote positive work environment.
- Preparation & checks of documentations like functional logic, hardware design specification, and software design specification, and PLC Validation document, panel inspection protocol.
- Captured technical schematics for use in project planning and execution.
- Techno-Commercial co-ordination with design, procurement, Hardware Selection & Vendor Management.
Sales Application Engineer
SunSui Process Systems
Pune
06.1997 - 03.1998
- Offered product development input based on understanding of customer needs and collaborated with suppliers to determine and execute product concepts.
- Managed sales-based interactions with customers and followed up on new business opportunities.
- Recommended changes, improvements or enhancements in products to product development team based on customer feedback.
- Identified sales opportunities by assessing environment and devising and implementing winning strategy.
- Demonstrated respect, friendliness and willingness to help wherever needed.
Education
Bachelor's of Engineering - Instrumentation & Controls
North Maharashtra University
Jalgaon, India 05.1993 - 05.1997
Skills
Lean Manufacturing, Workflow Development
Project Management-planning initial flow to initial flow control leading to full control
Instrumentation & Electrical
Industrial Automation-PLC, SCADA, VFD, Servo, safety PLC, barriers, BMS, fire alarm, IIOT, Industry 40, SQL Database, Python, VB Scripting
Managing Cross Functional skills
IMS Implementation, EHS Management
Control systems understanding
Digital Transformation, Designing interfaces
Solution development for shop floor operations
Microsoft SQL Server, Python, VB Script
Data Collection, reports design
Object-oriented solutions
Robotics Customized Application development
Software
Siemens PLC S7-200,300, 400, 1200, TIA Portal, Simatic Manager, WinCC, Sinamics, Motion Control Drives, Servo, Starter
Mitsubishi PLC Fx Series PLC, HMI, MR-E Series Servo, GX Works 2, MR Configurator, Medoc, E-Designer
Python, VB Scripting, SQL Database Connectivity
Schneider-PL7 Pro/TwidoSoft, Indusoft SCADA, Proface HMI, Delta-WPL Soft, ABB-Automation Builder, Emotron, Crompton, Selec, Renu,
Communication protocols: RS232, RS 485, Ethernet, DF1, DH485, MPI, Profibus, Profinet, OPC, Modbus, BACnet, Melsec
Certification
WCM Instructor
Interests
Process Optimization & Data Analysis
Efficiencies Savings, Cost Deployment/Identify losses & waste & methods to minimize at optimum cost
Digital Transformation/Equip Prioritization/Risk Register
Process Automation-Minimize Human Efforts/Productivity Improvement
Analytical/Logical Thinking in structured manner/Root cause analysis
Maintain Working Environment by encouraging team
5S, EHS culture, 3G, OPL, QK, 5W1H methodologies
Skill Matrix, Training Need Identification
Accomplishments
- More than 24 years of Project & Engineering Management, and Leadership experience in manufacturing environments and plants. Accomplished repeatedly successful increase in Safety, Reliability performance, productivity, quality and customer satisfaction.
- Completed the project successfully as a engineering consultant for new gypsum plasterboard plant capacity of 15 Mn SQM/annum first Indian plasterboard manufacturing plant of such capacity in India. The final plant commissioning done in Jan 2018.
- Operation & Engineering contract of 5 years for running the plasterboard plant efficiently. Accomplished task successfully by our team of engineers with continuous improvements.
- Successfully completed the projects in paint, chemical, glass, steel, rubber, tyre, petrochemicals, gypsum, metro, airport, pharmaceutical industries, Machine manufacturer, OEM etc,
- Joined M/s Saint-Gobain as “ Lead Engineer-Instrumentation ” in June 2008. Promoted to “ Manager-Electrical & Instrumentation ” in Jan 2010.
- Awarded for the “ performance of excellence ” in 2010 by Managing Director of Saint-Gobain Gyproc
- Entrusted with the Production responsibilities & promoted to Manager-Production Operations in Nov 2013.
- Enhanced EHS culture with critical risk reduction, Hazard identification & risk assessment to become safe working environment.
- Successfully completed certification course “PM practitioner” by WCM worldwide forum.
- Recorded best performance of plant in terms of key RM usages & optimization in the global benchmarking report.
- Achieved efficiency savings of INR 3.24 per SQM on key RM usage & INR 7.70 per SQM on total savings w.r.t budget 2014 in the first half of the year 2014.
- Achieved efficiency savings w.r.t budget 2015: Particulars % Savings w.r.t budget: Increase in production volume over budget 2.48%, Reduction in Cost over budget 20.18%, Reduction in usage in Major RM 3.49%, Increase in NSY over budget 0.84%
- Achieved ever highest production, best plant reliability, ever lowest Wet Scrap.
- Awarded with best improvement in Energy Index in the world for Plasterboard in the WCM Asia Forum at Laem Chabang, Thailand.
- Headed as a “Management Representative” for IMS Implementation & certification Successfully.
- Achieved series of quantifiable accomplishments as Electrical & Instrumentation Manager within group by 12% overall equipment reliability & raised to a world-class status, 40% reduction in the overall maintenance cost, significant improvement in MTBF & MTTR.
- Leaded successfully various WCM projects and conducted significant process improvements with world best specific fuel consumption within Gyproc group.
- Early Equipment Management Pillar Owner and active team member in Safety, Quality, Cost Deployment, Autonomous maintenance, Professional maintenance, Focused Improvement pillar.
- Completed White Cap “Instructor Course-WCM” by WCM worldwide conducted at Thailand.
Timeline
Founding Director-Industrial Automation Company
Bhanuleelai Technologies OPC Pvt. Ltd.
07.2022 - Current
Manager-Production Operations
Saint Gobain Gyproc India Limited
06.2008 - 07.2016
Head-Electrical & Instrumentation
Christ Nishotech Water Systems India Pvt. Ltd.
03.2007 - 06.2008
Sr. Executive-Engineering
Bharat Serums & Vaccines Limited
02.2004 - 03.2007
Lead Engineer-Automation
Metalchem Industries
04.1998 - 02.2004
Sales Application Engineer
SunSui Process Systems
06.1997 - 03.1998
Bachelor's of Engineering - Instrumentation & Controls
North Maharashtra University
05.1993 - 05.1997