Quality & Process Control Lead with 22+ Years Experience

Dnyaneshwar V Shahane

Mobile: +91-965*******/866-***-**** ~ E-Mail: *******************@**********.***

Senior level assignments in Process Control Design, Development, Operation, Maintenance & Project entire plant with an organisation of repute

Location Preference: Pune/Nashik/Aurangabad

Executive Summary

A professional with over 22+ years of experience in operation, maintenance, Process Control & project.

Currently serving Horizon Automation Pvt Ltd as Site In-charge.

Conducting the Site planning, plant start-up and shutdown activities, efficiency monitoring and control, trouble shooting and de-bottle necking, safety, health & environment system.

Skilled at executing multiple tasks and projects simultaneously in challenging environments with excellent relationship management skills and the ability to relate to people at any level of business and management.

Keen planner, strategist and implementer with demonstrated abilities in Site activities.

Areas of Exposure

Planning and implementing day to day general Site Project Activities.

Managing the inventory of spare parts, material inspection & approval for project site.

Career Contour

Horizon Automation Pvt Ltd from Sep.2022 as Site In-charge

Accountabilities

Planning and implementing day to day general Site Project Activities, Online Line Support, Troubleshooting & Fault Findings

Design & development of Allen Bradly & Siemens PLC

Managing the inventory of associated spare parts Allen Bradly PLC & HMI required to Panels, material inspection & approval for project site

Project done in Body Shop of the Tata Motors Chinchwad: Duration-22 months

Project done in Body Shop of the Mahindra & Mahindra Chakan: Duration-8 months

Project done in Car Assembly of the Hyundai Motors Talegaon: Duration-4 months

Project WIP in EV Car Battery Module of the Mahindra & Mahindra: July2025

Pushpam Foods & Beverages Pvt Ltd from 20.06.2021 to 20.09.2021 as Maintenance Executive (O & M)

Accountabilities

Line1: Aluminium 2 piece cans, Line2:Hot/warm fill PET containers, Blow moulding, Fully auto Reverse osmosis water plant, in line homogenizer, Tunnel pasteurizer, tray packer, CIP system, 4.5/2 TPH boiler, HP/LP compressor,60/40 TR chiller, 1250kva transformer, 320kva DG set, WTP/ETP

Highlights

In house ETP renovation, 40 bar ABC /CP LP compressor 60/40/20/10 TR chiller, HVAC servicing

CSD line installation & commissioning

Implementation of preventive & breakdown maintenance system

Prabha Engineering Pvt Ltd, Pune July 2018 to June 2019 as Ass. Manager

Accountabilities

Managing the operations & maintenance of the auto electrical department, Blow & injection moulding, CCS, ultrasonic welding, spm, winding, sheet metal press shop, ABB make welding robots & entire utility, VCB, Transformer 1000KVA with OLTC, ACB. Material handling equipment, compressor 100CPV Chicago, LT, APFC, DG synchronization panels, EOT crane, Synchronization DG panel, chiller cooling tower, STP, ETP.

Highlights

Efficiently repaired micro controlled processor based obsolete controller of stator winding m/c for having cost 1.5 lakh.

Implementation of Tpm activities.

Implementation of preventive & Break down maintenance system

Project handled upto 1 cr. Mahindra wipper line, stp, etp, New fire hydrant system installation.

BorgWarner Emission Talegaon India Pvt Ltd, Pune 05.11.2012 to 13.07.2018 as Sr. Engineer

Accountabilities

Managing operation & maintenance of glow tube & heater rod pressing, heater rod reducing fully Automatic line, shell & heater rod pressing line, EGR line,Ecotec, Felss, Ima, Trumpf laser welding, mig o mat plasma jet welding, Fully automatic/semi-automatic siemens plc based Germany make spm machines, ac servo based pick & place units, utilities 500 KVA transformer, 160 KVA UPS, AMF unit, Harmonic filters, Fire hydrant, sprinkler, alarm protection system, 250/50 KVA DG set, battery operated mhe, BSE60 kaeser compressor, SAP modules, LOTO.

Highlights

Repaired in- house Obsoleted power supply card of mig-o-mat plasma jet welding & saved cost 2.5 lakh

Repaired in- house light energy measurements control card of haas Trumpf laser welding & saved 1.5 lakh

Repaired in-house Obsoleted DMF-P B100 Staiger Mohilo make force & displacement controller & saved cost 2 lakh

Repaired in-house Bosch amplifier card pv60 & saved cost 70000.

Repaired in-house Murr electronic DIO & saved cost 2 lakh.

Repaired in-house comcon90 compact plc of auto mgo feeding unit & saved 2 lakh.

S7 200,300,400 & step S5 of siemens Simatic plc program corrupt/reset problem, uploaded the program in plc in-house & saved the cost 1 lakh.

Obsoleted OP7, OP27 memory hang or program reset problem, uploaded program in-house & saved cost 2 lakh

Camera vision system malfunction, changes done in program in-house & saved cost 1 lakh

Repaired in-house compact valves cpv of Festo & saved cost 1 lakh

Festival check box program uploaded & saved cost 70000.

Obsoleted Kollmorgen ac servo drive upgraded into latest version in-house & saved cost 1.4 lakh

Basic parameters uploaded & encoder setting done with software & program in AC servo motor, saved 1 lakh

IATF certificated as internal auditor

Bagged the Best Employees Certificate.

Achieved Best kaizen award in plc/drive/controllers/camera vision system

Implementation of preventive & break down maintenance system

Collection of all software & programs from oem for diagnosis & trouble shooting purpose due to my own interest.

Project handled Upto 1 cr. EGR, Thailand line, LT panel, cabling installation & Commissioning.

Alicon Castalloy Ltd, Pune 16.01.2011 to 31.10.2012 as Sr Engineer

Accountabilities

Performed operation & maintenance die casting hpdc, lpdc, furnace, Machining shop & entire utility, 4000KVA DG & Transformer, Atlas copco compressor, Fire hydrant system, eot crane, material handling equipment, SAP.

Highlights

Implementation in maintenance through innovation & proper method

Implementation going on energy efficiency improvements projects

Knowledge of energy efficiency calculations

M-Tech Innovation Ltd, Pune 19.08.2008 to 30.11.2010 as Sr Engineer

Accountabilities

Managing the operations & maintenance of kora packmat, chip module laminator cml-200, Chip module punch cmp-200, card milling & Implanting cmi-200, mpr-5000, perfecta shearing, Genius 52 uv, sormz offset printing, burkle lamination, imaj/videojet printer, uv dryer & entire utility York chiller 150,180 kw, 100hp kaser compressor, 630 kva DG/Transformer, scada chiller monitoring, Fire hydrant system, BMS system,STP,ETP, VCB, ACB,MCCB.LT,AMF,APFC panels.

Highlights

Implementation going on energy efficiency improvements project

Implementation in maintenance through innovation & proper method

Suzlon Infrastructure Services Ltd, Pune 11.12.2006 to 18.08.2008 as Senior Engineer

Accountabilities

Managing the operations & maintenance of the 0.6 MW, 1.25 MW, 1.5 MW capacity wind turbine generator, 33 KV Substation, Switchgears & equipment,SF6 circuit breaker, VCB, power transformer 650/750/1000/1250/1500 KVA, CT, PT, LA, Isolator, Protection Relays, Cooling & Hydraulic System, Sensors, Variable Frequency Drive / PLC Batchman (Suzlon Control System), SCADA, SAP modules.

Performing instrumentation and automation, erection & commissioning of wind turbine generator, slip ring, equipment calibration, fault finding techniques, generator, transformer, digital PID temperature controller, digital energy meter, control panel, power panel, Capacitor panel and small PLC programming, soft starter, yowing & pitching mechanism.

Highlights

Efficiently resolved PLC problem for having cost 1.5 lakh.

Performed Shield separation, spike guard, Battery bank of blade pitching modification and Kaizen in wind Turbine Generator.

Certificate for outstanding performance, productivity & dedicated services of the year 2007

Achieved Best kaizen award in wind Turbine Generator

Project installation & commissioning of WTG

BG Appliances Private Ltd, Aurangabad 16.12.2004 to 06.12.2006 as Engineer

Accountabilities

Performed operation & maintenance auto insertion department of Radial insertion machine, Axial insertion machine, sequencer machine, GT pin & eyelet insertion machine, ICT machine & plant maintenance 500 KVA DG/Transformer, ELGI 22-8.5 compressor.

Highlights

Repaired microprocessor card of Radial Insertion spm TDK & saved cost 1.0 lakh

Bagged the Best Employees Certificate.

Dhoot Transmission Private Ltd, Aurangabad 01.10.2002 to 01.10.2004 as Trainee Maintenance Engineer

Accountabilities

Performed maintenance of fully automatic wire Processing stripping Cutting Crimping Machine, Extruder Machine, moulding and Plant Maintenance.

Highlights

Repaired microprocessor card of fully automatic wire processing spm Komax machine & saved cost 1.5 lakh.

Academic Credentials

B.E. (Electrical, Electronics & Power) from Government Engineering College, Aurangabad with 61.2% in 2002

Trainings Undergone

EHS, QMS and Lean Management (including 5S) while working in Suzlon.

Special purpose CNC machine maintenance while working in Videocon.

IATF, HIRA while working in BorgWarner

IT Skills

Operating System: MS-DOS, Windows 98/2000/XP

Packages: MS Office 2000, AutoCAD

Personal Dossier

Date of Birth: 2nd June 1976

Address: Nisarg Alliance, Flat No-104 B Wing, Choudhari Park, Wakad 411057 Pune.

Linguistic Abilities: English, Marathi and Hindi

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