Maintenance Management

Pankaj Patil

B.E. (Mechanical Engg), DME,

Certified Energy Auditor (BEE)

C-PGDBA - Operations (Symbiosis, Pune, India)

Address

**,**** *********.

Gangapur Road,Nashik, MS, India.

Pin code – 422013

+919********* (M)

***************@**********.***

Key Skills:

Certified Energy Manager & Auditor (BEE, EA-10059), HVAC,

Energy Management System – BS EN 16001, Renewal Energy Projects, Plant Maintenance, Projects Management, Operation and Maintenance of Utilities, Facility Management. Implementation of OHSAS 18001 and compliance to ISO TS 16949, ISO 14001,ISO 9001, Strong analytical problem solving skill, Leading team of skilled and unskilled labors, Knowledge of financial concepts.

Objective:

To be able to contribute to the organization effectiveness by achieving specific goals in accordance to the ethics and core discipline of organization. To be a part of the organization growth and development by using my knowledge, skills and experience to the best of my abilities.

Experience: 8 Years, 1 month at Bosch Ltd, Nashik.

Present designation:

Senior Engineer in Facility Management Dept. Bosch Ltd, (Diesel system) Nashik. Energy Manager and Auditor.

Bosch Ltd, Nashik is leading manufacturer of diesel fuel injection equipments for

automotive and stationary diesel engines.

Roles and responsibilities:

Certified Energy Manager (Nov 2008) & Auditor (May 2009):

Coordinator plant energy management team. Monitoring and controlling specific energy consumption of plant, Energy audit of utilities. Identifying, implementing and monitoring energy conservation projects in the plant. Generating innovative ideas for Energy Conservation. Creating energy conservation awareness among employees. Core team member for CO2 emission reduction of Bosch Diesel System worldwide. On line compare, assess and review our CO2 management program with other Robert Bosch plants (Germany, France, Turkey, China, South Korea, Japan) Completed around 10 projects of energy conservation in HVAC & process chillers with saving of 2500 MWh/year

Major duties as Energy Auditor at Bosch Ltd:

• Develop, manage and continuously refine energy audit programs, procedures and work processes to identify energy reduction projects and resource minimization strategies to reduce the environmental impact of machines and processes.

• Interaction with operation and maintenance team to review documents (i.e., drawings, equipment inventories, recent maintenance activities, major project plan), document occupancy use schedule and trend.

• Analyze historical energy use and consumption patterns. Identify abnormalities and research causes as required. Compare historical patterns to determine energy use intensity, targets for improvement.

• Perform thermal imaging surveys of building envelope, electrical panels, other areas or equipment as needed. Conduct air balancing tests and related field inspections of critical equipment. Oversee the installation and use of temporary metering and electrical measurement equipment. Trends performance result and develop recommendation for improvements in operation or equipment.

• Develop detailed Energy Conservation Recommendations based on inspections and measurements of equipment performance. Calculate accurate Life Cycle Cost analysis, Return on Investment calculations and applicable utilities rebate or incentive programs for all recommendations.

• Perform calculations to forecast peak load requirements for primary building equipment including mechanical and electrical systems. Develop preliminary strategies or alternatives to address deficient conditions.

• Prepare reports with detailed findings for specific energy performance modeling and testing, as well as established department standards. Finalize report following established internal review process.

• Present reports and findings to management, review energy analysis methods, recommendations, and implementation plan.

• Implement identified projects.

Major Energy Audit (Energy Conservation) projects:

• Installation of VFD for blowers of evaporative cooling system workshop. (Energy saving : 577.5 MWh/annum)

• Centralized chiller plant of temp 18°C (with VFD for pumps) for cooling of cutting oil instead of decentralized chillers (low evaporator temp) for heavy metal cutting machines. (Energy saving : 502 MWh/annum)

• Chiller replacement of hydro erosion machining lines with centralized water chillers (temp 7°C) & use of high surface area heat exchangers for cooling of slurry. (Energy saving : 60 MWh/annum)

• Elimination of heat source from conditioned area, use of cooling tower water for cooling of cutting oil at 30°C instead of air cooled chiller. (Energy saving : 263 MWh/annum)

• Elimination of spindle cooling units (hot gas by pass chillers) system with centralized energy efficient chillers. (Energy saving : 310 MWh/annum)

• Installation of ON/OFF timers for offices AC. (Energy saving : 100 MWh/annum)

• Air cooled chiller replacement from AC workshop of precision mfg and installing VFD for chiller pumps. (Energy saving : 335 MWh/annum)

• Optimization of duct heater setting of clean room HVAC. (Energy saving : 210 MWh/annum)

• Avoiding hot and humid air ingress through conveyor opening in AC area (Energy saving : 220 MWh/annum)

• Energy efficient pumps for cooling tower (Energy saving : 70 MWh/annum)

Plant maintenance - Facility Management (Jun 2007 to till date): Preventive maintenance of cooling units, chillers, heat exchangers of various production machines. Improving utilization of production machines through preventive maintenance. Use of predictive maintenance techniques for central plants (like chillers, BMS, HVAC). Process mapping of various systems, deriving indices in terms of cost, effectiveness. Use of SAP plant maintenance module.

• Maintenance of cooling units, heat exchanger, electrical panel cooler on various machines like multi spindle auto mats, gun drilling machine, grinding machine, LASER machines, assembly lines.

• Maintenance of centralized and decentralized water / oil chilling plant.

• Maintenance of cooling towers, pumps, heat exchangers, liquid nitrogen system, deep freezer etc

• Maintenance of HVAC : Ventilation plants, evaporative cooling systems, clean room, server room packaged AC, AHU, exhaust, blowers etc

• Compressed air services, refrigerated dryer for compressed air.

• Water supply system to plant.

• AMC management of above systems

Operation: Air compressor, Hot water generator, Fork lifts, HVAC system (chiller plant for process, chiller plant for clean room, packaged AC, precision AC for server rooms, room AC, VRF system)

Spares management, Budgeting & Cost control, MIS preparation.

Exposure to TPM, BPS (Bosch Production System – Lean Manufacturing System), practicing 5 S and KAIZEN (CIP) at workshops.

DBE: Compliance to deployment of business excellence (DBE) Diesel System of Bosch, strategy to success and results, monitoring and controlling Key Performance Indicators (KPI)

Compliance to ISO- 14001, OHSAS – 18001, ISO TS 16949, ISO 9001 for Facility Management. – Core team member for implementation for OHSAS 18001. Risk assessment of utilities, Safety training for associates Dept coordinator for ISO TS 16949, ISO 14001, ISO 9001.

Facility Management Projects (Sept 2003 to May 2007) Planning and execution of infrastructure projects for manufacturing set up, such as, ventilation system (evaporative cooling), air washer, clean room, air conditioning, VRF system, precision air conditioning, office air conditioning, centralized water chillers, oil chillers, cooling towers, D G sets, compressed air services, compressed air dryer, service lines of utilities

Compliance to corporate guidelines for utilities and building (Robert Bosch, Germany), obtaining approvals from corporate experts about major changes in buildings and utilities.

Project involves, coordination with end user, requirement study, floating enquiries, budgeting, formulating proposal, technical short listing of vendors for commercial discussion, technical review, co ordination with civil, electrical, safety dept. preparing work schedule, progress monitoring, execution in time frame, commissioning.

Types of project handled (Planning, installation & commissioning)

• Clean room of class 100,000 for precision assembly of area 1000 sq. m having 200 TR air-conditioning load, BMS system for plant.

• Clean room of class 10000 for various standards room, server room to maintain precise temp. 20 ± 0.5° C and RH 45 ± 5%, Air conditioning of the various offices, VRF system

• Energy efficient ventilation system (600000 cfm, 650000 cfm etc) of the large workshops such as 16000 sq. m, 10000 sq. m. area.

• Centralized water chilling plants (total capacity 2500 TR), cooling towers plants(total capacity 3000 TR) for various production machines, AC plants.

• Liquid Nitrogen storage vessels for cryogenic treatment.

• 2000 kVA Cummins D G set.

• Implementation of SAP for maintenance purchase requisition, work orders and plant maintenance module.

Process planning (Sept 2002 to Aug 2003):

Worked as trainee engineer in process planning of diesel injector assembly dept, and diesel nozzle manufacturing dept. Job involved process planning for imported assembly benches and tooling required for multi spindle automats, gun drilling machines and mechanical presses. Productionisation of various machines relocated from France.

Computer proficiency:

MS office, MS project, Auto cad, SAP

Achievement: Winner of “DS Appreciation Award 2009 for Energy Efficiency and CO2 Reduction.” This award was given by Bosch Diesel System for excellent innovative energy conservation project and reduction in CO2 emission.

Educational credential:

C PGDBA (Operations): Corporate Post Graduate Diploma in Business Administration from Symbiosis, Pune, (2008 to 2010)

Bachelor of Engineering (Mechanical):

S. S. G. M. College of Engineering Shegaon, 2002, with 70.6% First class.

Amravati University, M S.

Diploma in Mechanical Engineering:

Government Polytechnic, Khamgaon. M S, 1998 with 73.12% First class.

S S C: L B C Vidayalaya, Malkapur M S, 1995 with 84.57% Distinction

Professional training:

• HVAC TAB (Testing, Adjusting and balancing), Heat load calculation.

• Energy Management System BS EN 16001

• Energy Management and Building codes (ECBC)

• OHSAS 18001

• Bosch Production System

International assignment (Sept 2006):

Visited Robert Bosch South Korea plant for study of utilities, clean room, energy management and maintenance practices

Present salary: Rs 7.3 Lacks/annum

Personal details:

Date of birth: 15.12.1979

Gender: Male

Nationality: Indian

Marital status: Married

Passport: Yes

Interest:

o Playing table tennis, cricket.

o Watching engineering and scientific programs on T V.

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