**** ********** **. • Independence, KY *****

Phone 859-***-**** • E-mail twn21q@r.postjobfree.com

Santosh K. Prasad

Professional controls engineer

Experienced Controls Engineer with a 10-year record of success in implementing breakthrough process and controls improvements and cost savings for manufacturing facilities. Expert in automated controls design and implementation. Known for innovative engineering, problem solving, complex troubleshooting, project leadership, training, excellent communications skills and documentation. Provide leadership to drive continuous technical, process, quality, safety, and productivity improvements. Currently working in Automotive Manufacturing to continuously improve quality, productivity and eliminating downtime in a safe environment.

key skills and knowledge

- Controls Engineering - Lean Manufacturing - Production and Quality Support

- Project/Launch Management - ACAD Electrical Drawing - Technical Support and Training

- Error Proofing & Poke Yoke - PLC & HMI Programming - Leadership & Communication

- Sophisticated systems integrations - Toyota Production System - Allen Bradley/Siemens/G&L

Professional experience

Multi-task projects to achieve plant objectives. Make controls and process modifications to automated/manufacturing equipment to reduce cycle time, scrap, and implement error proofing to ensure quality. Make controls modifications for product engineering changes to include trial runs and run offs. Update prints, documents and programs. Create technical and operating instructions on equipment changes. Support Production, Material, Quality, and Process Engineering and Maintenance departments to include training. Supervise capital investment projects. Specify, cross reference, stock, order, purchase and setup spare parts. Create preventative maintenance schedules and procedures. Troubleshoot equipment failures to maintain production goals.

Faurecia Automotive Seating July 2006 to Present Walton, KY

Sr. Manufacturing Controls Engineer

Completed $30K savings with value added controls engineering changes in 2008.

Member of plant engineering team for BMW Equipment launch & production ramp up to annual sales of $53M.

Key player in Hoshin teams. Made suggestions/implemented controls & process changes for BMW increased production requirements by 35% without major capital investment.

Created specifications/bid package for two BMW Bar Code pack stations at $30K each for product traceability. Supervised installation and start up. Trained operators, quality and maintenance associates.

Changed controls and manufacturing processes to achieve mixed model scheduling with SMED based line changes. This significantly improved overall production capability and Pieces Produced Per Hour.

Engineered and installed controls for automatic door on function tester as ergonomic improvements and cycle time savings. Received best improvement idea of the month. Made HMI & PLC changes for product revisions.

Updated Honda product function tester servo motors to replace obsolete parts. Added UPS’s to key equipment.

Supported AGREPT studies (Ergonomic Improvement projects), Hoshin, Kaizen and QRQC (Quick Response Quality Control) workshops. Recognized for Best Improvement Idea of the Month.

Primary Content Expert for all plant’s PLC’s, power systems, electronic equipment & components programming.

Support all Process, Weld, Facility Engineers, management, production, quality, materials & maintenance groups as needed to ensure OEE, and product quality and lean manufacturing in a clean and safe environment.

Review warranty/product issues with quality department & make controls/process modifications required for producing quality parts. Implemented frequency band checks for vibration on BMW function tester to reject bad motors form supplier. Implemented poke yoke checks for part presence on Honda function testers. Implemented flags checks on equipment sensors to detect stuck on or off failures to improve equipment reliability and quality.

Act as Engineering/Maintenance manager during his absence. Auditor for monthly Engineering Department 5-S and safety audits. Manage improvement idea tracking for our production group.

Perfetti Van Melle June 2002 to July 2006 Erlanger, KY

Electrical Project Management Leader (Process Controls Integrator)

$500K Capital project for sugar grinding operations of granulated sugar to 6X sugar.

$1M Capital project for 3000lbs/hour batch mixing, candy extrusion and packaging in our remote Buffalo Grove, Illinois facility for Air Heads Extreme product.

Electrical/Controls Engineering leader for $2M facility & manufacturing equipment rebuild after silo explosion.

Relocating two manufacturing lines & batch mixing upgrade of Air Heads Extreme product from Buffalo Grove, Illinois to Erlanger Kentucky.

Electrical project management of Air Heads bubble gum relocation from Italy to Erlanger, Kentucky facility.

Added additional candy recycling system to reduce waste, resulting in $25K annual savings.

On team for start ups, debugging and installations. This included training production, quality, management and maintenance associates.

Electrical Controls Engineer

Increased maximum throughput on 2 Air Heads product extruders from 2800lbs/hr. each to 3200lbs/hr. eliminated bottleneck for Air Heads line capacity increasing overall production & PPH driving up efficiency 15%.

Engineered changes to allow for new size Air Heads bar to be run with no capital investment.

Upgrade Allen Bradley obsolete PanelView to current PanelView Plus product.

Adjust PID loop for extruder heating controls for stable temperature deviations. This ensured consistently cooked product and quality.

Installed additional flavor and color mixing tanks to reduce change over time. Involved PLC, HMI changes. Installing and configuring frequency drive. Creating drawings, technical and operational documentation.

Improve and maintain dry and liquid delivery systems.

Contract Professionals, Inc March 2001 to June 2002 Moraine, OH

Controls Engineer/Plant Start-Up

Member of General Motors Error Proofing System Engineers. Embedded Support Engineer. Job functions include production support, training, troubleshooting. Also responsible for controls projects on process tools / conveyors which include ControlLogix PLCs, controls and network based systems.

Rockwell Automation August 1999 to March 2001 Cincinnati, OH

Field Service Engineer

On site applications engineering of Rockwell/Allen Bradley hardware and software products. Involved controls, network integration, systems start-ups, servicing, proposal development, documentation and AutoCAD drawings. Embedded engineer at General Motors on error proofing systems. Included installation, debug and start up of General Assembly plant. Error proofing was done using PLC and network based systems including Device Net, Control Net and Ether Net communications integrated with production/conveyor systems and server applications. Conducted Customer specific Factory Certified training on wide range of AB Controls Systems integration.

R. A. Jones Company, Inc. June 1997 to August 1999 Covington, KY

Field Service Technician

Installed high speed automated packaging systems with drives, servos, & PLCs. Software/hardware troubleshooting, technical support & training was provided. Developed the ability to resolve control system start up & debug issues in a timely manner. Worked with engineering department on field logic & wiring change/updating as built drawings.

Motorola June 1994 to June 1997 McHenery, IL

Technical Operator

Designed/built test stations, prepared schematics & documentation; analyzed product failures, upgraded calibration capabilities of product test stations. Testing processes used HP test sets used in Cellular communications.

education

ITT Technical Institute May 27, 1991 to May 27, 1994 Indianapolis, IN

Bachelor of Applied Science in Electrical Engineering Technology

National Vocational Technical Honor Society, GPA (3.7/4.0).

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