- 906-***-****

- ac69vs@r.postjobfree.com

www.linkedin.com/in/rohan-kulkarni1993

ROHAN KULKARNI E.I.T.

SUMMARY

1.Master of Science in Chemical Engineering with two years of Professional Experience looking for full-time opportunities.

2.Specialized in Process Modeling and Plant Economics (cGMP/ Process Improvement / Lean Manufacturing/ Quality Engineering/ HAZOP studies) and Production, Manpower handling and supervising the team using industrial tools

3.Worked in a regulated environment for process validation, project management, process modification and internal auditing

4.Skilled in Membrane Bio Reactor, Process Optimization, PSM implementation, Method Validation, FMEA, Statistical Analysis

5.Proficient in Aspen Plus, Unisim, Aspen Hysys, Minitab, AutoCAD, CHEMCAD, MATLAB

EDUCATION

MS in Chemical Engineering (GPA: 3.55/4) Michigan Technological University May 2018

BE in Chemical Engineering (GPA: 7.36/10) Gujarat Technological University May 2015

CERTIFICATION

● Fundamentals of Engineering certification from NCEES- MI Board, Certification ID 19-014-57

● Aspen Plus- Process Modeling and Oil & Gas Economics certification from Udemy

● SAChE- Process Safety Management (PSM) certification from AIChE

TECHNICAL SKILLS

Industrial Skills: Yokogawa DCS, PLC controlling, Preventive Maintenance, Work Permits, Project Management

Regulations: OSHA regulations, Environment Health and Safety (EHS), DOT, FDA, ISO 9001

Quality Tools: Statistical Data Analysis, Six Sigma tools, DMAIC methodologies, Design of Experiments, Statistical Process Control

Lean Tools: COMMWIP, 5S, TOC, Visual control, Root Cause Analysis, SMED, FMEA and Poka-yoke, kaizen, Standard work.

Computer Software: Microsoft Office, Auto CAD, Visio, MATLAB, Minitab, Unisim, Aspen Hysys, Aspen Plus, CHEMCAD

Professional Experience

ChemDesign Products Inc., Marinette, WI, USA Engineering Intern May-Sept 2017

Hands on experience in preparing punch list for Management of Change(MOC) for the new products and validating the changes

Participated Process Hazard Analysis(PHA) team and carried out documentation of appropriate changes if needed

Reviewed Standard Operating Procedures(SOPs) followed Process Safety Management (PSM) standards

Developed and assisted for Engineering Drawings (BFD, PFD and P&ID) (Brownfield plants) for various products

Supported operations team for plant optimization, troubleshooting, efficiency improvement & problem solving.

Implemented and evaluated changes in existing processes designed to enhance productivity, safety or product quality.

Atul Ltd – Aromatic Division, India Production Engineer May 2015-July 2016

Using DCS monitored daily production, collected and analyzed data to recognize trends and potential problem.

Performed process analysis and auditing for improvements in manufacturing efficiencies, quality and cost reduction.

Responsible for Handling of Deviations, Standard Operating Procedure (SOP) and maintaining batch records

Managed temperature and humidity mapping, calculated MKT and determined the hot spot/cold spot for the warehouse.

Supervised and enforce all safety standards, environmental federal regulations and training personnel in assigned units

Provided technical support for troubleshooting production line to ensure smooth daily operations in the plant

Atul Ltd – Aromatic Division, India Engineering Internship Project June 2014- April 2015

Objective: To improve the steam economy of Multiple Effect Evaporator by developing various cost-effective techniques.

Worked on Material and Energy Balance. Using Excel provided solutions for different schemes.

Simulated the system using Unisim for backward scheme Multiple Effect Evaporator setup for conforming the results

Impact: Implemented backward feeding scheme for the MEE in plant improved the steam economy from 1.1 to 1.4.

Vasa Pharmachem Pvt. Ltd, India Process/ Production Engineer May 2013- April 2014

Installed process equipment and supported the conduct of IQ, OQ, PQ validation activities and the documentation

Coordinated with various departments like manufacturing, QA, QC, R&D for the engineering and validation aspects.

Supported key QA/RA activities as assigned including CAPA investigations, Documentation Control, and Training

Conducted internal audits and training, maintained proper documentation and Batch Manufacturing Record(BMR)

Developed process design basis, utility summaries, inputs and outputs for different process schemes.

Prepared and developed P&ID and PFD, process design calculation, line sizing and pressure drop calculations

Established and Maintained significant KPIs: Downtime - Decreased by 90%, Near Miss reporting- Increased by 145%.

Research Experience

Membrane Bioreactors(MBR): Challenges and Opportunities

Currently I am working with Dr. Andrea Da Costa on Membrane Bioreactors(MBR) that has wide range of applications

My work will focus on the challenges of MBRs and particularly on developing a good understanding and data analysis of energy consumption issues and opportunities to optimize and reduce cost, thus improving commercial viability of Ultrafiltration

My work is primarily based on literature review, laboratory experiments, process simulations and economic analysis of MBRs.

The impact of the research will be on the waste water treatment industries, upstream manufacturing, and many more

Laboratory Experience

Michigan Technological University Research Assistant Dec 2016- May 2018

Followed GLP (Good Laboratory Practices) to conduct routine physical/chemical/instrumental analysis.

Carried out R&D, designed experimental setups and conducted the experiments for alkaline leaching using ASTM standards.

Implemented and developed SOPs and ICH guidelines for lab analysis and facilitated periodical laboratory audit and JSA.

Prepared, conducted, documented, and presented data and results for analytical testing in accordance with GLP.

Trained with Safety data evaluation, risk identification, Process safety information, PSSR (Pre-start-up safety review)

Projects Worked on with Advisor Dr. Timothy Eisele

Recovery of Lead from Recycling Slag, RSR Corporation

Phosphorous Removal from Iron ore, Arcelor Mittal group

Finding contact angle between the coal particle and different surfactants

PROJECT BASED TECHNICAL EXPERIENCE

INDUSTRIAL PROJECT MANAGEMENT

New Process Development: Pilot Plant process set-up for a continuous extraction process

Objective: Coordinated with R&D team for the pilot scale plant set-up of the continuous extraction unit

Reduced the amount of toluene (solvent) in the waste by substituting the batch extraction process with the continuous process, working with R&D team for process setup and data collection.

Performed IQ, OQ, Method Validation, Job Safety Assessment (JSA) and prepared SOP for safe operability

Impact: The new process improved the amount of solute and solvent recovered from the extraction process

Cost Improvement Project (CIP): Recovery of Toluene from Vent Stream in a vacuum distillation column

Objective: To recover maximum amount of Toluene from the vacuum fractional distillation column

Using Aspen Plus developed the distillation column model to check the amount of toluene that should be theoretically recovered based on feed mixture. Executed solutions for increasing the recovery.

Performed Cleaning of Condensers and coolers, installed new condenser connected with biometric leg of the distillation column.

Impact: Improved of toluene recovery by 10% that resulted in reduction of total amount of toluene consumed

ACADEMIC PROJECTS

Quality Improvement: Improve Board Dimensions measurement techniques, Saint Gobain

Objective: Analyze the scope of improvement in the existing system using statistical tools to meet quality standards

Utilized sampling statistics and measurement tool (Gage R&R) to develop X-bar and R-charts a part of Method Validation

Presented required reports detailing the effectiveness of existing processes and implemented supporting the need for a new process for meeting specifications.

Impact: Designed a new measurement technique that includes laser and no human errors for measurements

Process Simulation: Atmospheric Crude Column with side operations (Strippers & Pump Around) using HYSYS 8.0

Objective: The project involves ATM Crude Column to be construct, run, analyze and manipulated in Aspen HYSYS V8.0.

Atmospheric Crude Column are one of the most important pieces of equipment in the petroleum refining industry. It serves several cuts including Naphtha, Kerosene, Light Diesel, Heavy Diesel and Atmospheric Gas Oil

Added SIDE OPERATIONS such as 'Side Stripper' to improve quality of main products and 'Pump Around' to improve the column's efficiency.

Engineering Design: Process Optimization of Fluid Catalytic cracking unit

Objectives: Check whether the new refinery is capable of a sustained positive, before-tax profit in a cost-effective way.

Carried out Process modeling using different simulation software’s (Aspen Plus, Aspen Hysys, Unisim) for comparing the difference in the results and using different standards for the process simulation

Impact: Evaluated working and results of all three simulators and presented a report on total change in each process

Engineering Design: Wet Desulfurization of flue gas

Objective: Scrubbing of flue gas stream containing Sulfur dioxide to meet environmental regulations

Designed a process for scrubbing the sulfur dioxide to meet regulations we are using process simulation software CHEMCAD modeled a spray tower using Lime water mixture to scrub the Sulfur dioxide

Impact: The new process plant effectively meets the criteria of scrubbing the sulfur dioxide to the scale of 10-5

Lean Manufacturing: Starship Factory Simulation by implementing lean manufacturing principles

Objectives: Transformed an ordinary Starship factory to a Lean factory by applying various Lean Methodologies.

Implemented various lean tools starting with COMMWIP for waste identification than 5S, Theory of constraints for finding bottlenecks in the process, Process Failure mode effect analysis

Implemented Visual control, SMED and kaizen tools to improve the work efficiency of the operators

Impact: Reduced the non-value-added time by 32% and reduction in downtime by 20%.

LEADERSHIP

Volunteer Mind trekkers club and International Programs and Services (IPS), MTU

Member of LCI team responsible for continuous improvement programs around the campus

Worked as Student Manager in Dinning Services at Michigan Tech.

Successfully organized Career fairs under Training and Placement cell.

Soft Skills: Cross- Functional team, collaborate, communication skills, verbal communication, ability to collaborate, strong organizational skills, verbal communication skills, manage multiple projects

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