Satish Kumar Madriki

• Group of Companies for UPVC manufacturing unit FENESTA BUILDING SYSTEM as a Asst Manager for Overall Plant Maintenance activities which includes CNC machines for CNC Profile Cutting, CNC Profile Processing machines, Profile Fusion Welding machines, and Profile Corner Cleaner Machines, simultaneously with Utilities such as Air Compressor and DG
• Ensuring and Managing Multiple Maintenance Activities as a whole with Consistent and integrated implementation of Preventive, Predictive, Corrective and Breakdown jobs across Plant with different type of machines and its Operation
• Responsible for Preventive, Predictive, and Breakdown Maintenance of UPVC manufacturing CNC machines (Germany make, Italy make, and China Make)
• Ensuring the machines highest Quality output assurance with minimum breakdowns in day to day activities with the co-ordination from Production and Quality Team by effective maintenance planning.
• Planning and Commissioning of Ideal equipments in plants with Change in Control Systems by process of retrofitement in Electrical, Pneumatical and Mechanical parts
• Preparing the SOPS on machinery for do’s and don’ts during the preventive maintenance and as well as for the operator to avoid manual errors all time
• Studying the operation or manufacturing cycle time along with production and Quality team in order to maximize the production output.
• Participated in continuous improvement by generating suggestions, engaging in problem-solving activities to support teamwork.
• Used critical thinking to break down problems, evaluate solutions and make decisions.
• Preparing the Check-sheets and SOPS for operation and Maintenance of new and old equipments on the shop floor
• Key player in preparation and maintaining of the IMS documents as per ISO 19001 and 45001.
• Ensuring the machines Uptime which are bottleneck to the production by implementing TPM activities across the critical equipments of the plants.
• Maintenance of 11KV/433 V Ring Main Substation with Secondary source DG sets
• Ensuring all type of critical spares available at factory end to maintain and to avoid the prolonged breakdowns.
• Developing of Dashboards using GOOGLE STUDIO for various parameters of the machines data interpretations with its Uptime, MTTR, and MTBF also the RCA outcomes.
• Doing of Statistical analysis with data available on existing inefficient machine replacement in order to bring the latest technology machines developed in market for improving the productivity and ergonomics with smart manufacturing culture
• Eliminating the NVA which are time eating process in manufacturing line by the critical analytics and brainstorming sessions to improve the cycle time.
• Knowledge on basic Programming by using G and M coding for new set of profiles in the CNC machines for various type of operation as per the production requirement
• Planning the shift Schedules for technicians and making them engage in several activities apart from regular maintenance such Safety walk, training on PLC, Servo Motors, Servo Drives, Scada, VFDs and HMIs
• Developing the local vendors for converting the imported critical spares to indigenous manufacturing to reduce the maintenance cost
• Setting up of new Electrical panel with Erection and commissioning
• Accolades:
• Organizer – has organized tours and participated many cultural activities in college
• Mentored and coached entry-level and junior engineers to improve talent and boost skill levels.

• Responsible to Individually handle the shift for Mould Shop Unit, Sand Plant, Shot blasting machines, Pattern Shops, Stress relieving machines, Special Andromat Manipulator, and EOT cranes
• Role:
• Maintenance Management
• Supervising project related tasks including planning, control & troubleshooting for achieving the planned periodic schedules & process control; preparing project related budgets and ensuring adherence to the same
• Troubleshooting in foundry equipments such as Moulding Machine, and Shot Blasting Machine, Pattern Shops, and EOT cranes
• Individual shift handling for breakdown & running condition of automated HPML PLANT, supplied by Mls George Fischer, Germany
• Preparing the documents for EMS AND OHSAS
• Document preparation for 5’s activities
• Taking preventive actions as per scheduled shutdown job planning of replacements so as to avoid major breakdowns and as well as to reduce downtime
• Knowledge on basic Siemens S7 PLC
• Troubleshooting and PM in special type equipment such as Andromat [manipulator] and Stress Relieving furnace
• Installation and troubleshooting of variable frequency drives (MITSUBISHI)
• Making why-why analysis for all breakdowns and ensuring implementing of corrective action
• Enhance equipment and part reliability, extend life and suppress abnormal conditions or failure through MTBF & MTTR
• Troubleshooting and PM of EOT cranes, Magnet cranes, and lndef hoists
• Conveying systems such as belt conveyor, chain conveyor
• Basics of hydraulic systems and pneumatic
• Planning the improvement activities using 80-20 principle with respect to the breakdown trend
• Installation, Commissioning and Testing of Equipments
• Installation and commissioning of the CNC equipment with conducting of tests & inspections to ensure operational effectiveness of plant & utilities
• Reviewing Engineering Drawings, Layouts, Diagrams, Technical Specifications, Cost Estimates For Erection & Commissioning Of The Plant / Utility
• Identifying areas of bottlenecks / breakdowns and taking steps to rectify the same through timely and precise action.
• Conversion of PLC from step-5 to step-7 at high pressure GF Moulding line
• Listing out no of inputs and outputs in S5 system and updating the same in S7 system
• Conversion of program S5 to S7 with help of Actemium automation
• S7 Electrical panel were wired in house and commissioned within short period of time
• In this system by using distribute l/O configuration, we reduce considerable amount of wiring involved by placing input & output module close to the sensors and actuator, establishing the connection between plc

• Liaised with company executives and project managers to acquire resources to move projects forward.
• Communicated with industrial equipment installers to deliver technical support throughout project execution.
• Recommended improvements for design, construction means and materials based on field or changing conditions.
• Delivered concise instructions to technical team to maintain quality control.
• Recommended process improvements to reduce unnecessary waste.
• Monitored installation of materials and equipment for compliance with drawings and specifications.

Projects Handled:

· Installation and commissioning of the CNC equipment with conducting of tests & inspections to ensure operational effectiveness of plant & utilities.

· Reviewing Engineering Drawings, Layouts, Diagrams, Technical Specifications, Cost Estimates For Erection & Commissioning Of The Plant / Utility.

· Identifying areas of bottlenecks / breakdowns and taking steps to rectify the same through timely and precise action.

· Participating in the following:

o Cost Estimation & Budgetary Planning for the Project

o Basic Engineering, Detailed Engineering, Material Indenting, Enquiry Floating

o Preparation of Signal & I/O (input / output) list and cable schedule.

o I/O loop checking.

o Industrial automation network set up .i.e. OFC, Ethernet & Profibus.

· Anchoring the installation and connections of major instruments with help of vendors like HMI, PLCs, Servo Motors, Servo Drives, VFD, scanners, Pressure Switches, Encoders, Temperature Controllers, Proximity Switches, Limit Switches, Photo Electric Devices, Thermocouples & All Types of Valves.

· Executing load calculations and selection of cable size, grade, length and its type for LT, Control & Signal Applications.

· Troubleshooting and Installing of Pneumatic systems supplied Festo, Metal Work, Genetics, Pneumax.