Vikramjit Singh Aulakh worked as a Plant Engineer at Punjab Porcelain Ltd in Sangrur, India from August 2008 to May 2009. As the plant engineer, he was responsible for managing plant production, maintenance, and engineering tasks. He gained an understanding of the porcelain insulator manufacturing process and plant equipment. He worked to optimize production planning, improve equipment reliability, and reduce defects by closely monitoring the critical shuttle kiln operating parameters. His efforts included installing an extra blower on the kiln to increase its reliability.
Vikramjit Singh Aulakh worked as a Plant Engineer at Punjab Porcelain Ltd in Sangrur, India from August 2008 to May 2009. As the plant engineer, he was responsible for managing plant production, maintenance, and engineering tasks. He gained an understanding of the porcelain insulator manufacturing process and plant equipment. He worked to optimize production planning, improve equipment reliability, and reduce defects by closely monitoring the critical shuttle kiln operating parameters. His efforts included installing an extra blower on the kiln to increase its reliability.
Vikramjit Singh Aulakh worked as a Plant Engineer at Punjab Porcelain Ltd in Sangrur, India from August 2008 to May 2009. As the plant engineer, he was responsible for managing plant production, maintenance, and engineering tasks. He gained an understanding of the porcelain insulator manufacturing process and plant equipment. He worked to optimize production planning, improve equipment reliability, and reduce defects by closely monitoring the critical shuttle kiln operating parameters. His efforts included installing an extra blower on the kiln to increase its reliability.
Career Episode 1 VIKRAMJIT SINGH AULAKH, MECHANICAL ENGINEER
COMPETENCY DEMONSTRATION REPORT
DECLARATION: All statements of fact in this report are tre an! correct an! I ha"e ma!e claims of ac#ire! competencies in $oo! faith% The report is all m& o'n 'or( an! is a tre representation of m& personal competence in 'ritten En$lish% I con)rm that I n!erstan! that mem*ers of the en$ineerin$ team in Astralia are re#ire! to !ispla& a commitment to e+ercisin$ professional an! ethical responsi*ilit& in all aspects of their 'or( I also n!erstan! that !ocmentation s*mitte! in spport of m& application ma& *e referre! to the Astralian Department of Immi$ration an! Citi,enship -DIAC. for inte$rit& chec(in$/0%
Printed Name : 1I2RAM3IT SIN45 A6LA25 Signature : _________________________ Date : _________________________ Career Episode Report 1- Vikra!it Si"#$ A%&ak$ 'a#e 1 o( ) Career Episode 1 VIKRAMJIT SINGH AULAKH, MECHANICAL ENGINEER Career Episode Report 1- Vikra!it Si"#$ A%&ak$ 'a#e * o( ) Career Episode 1 Punjab Porcelain Ltd, Plant Operations Para% No% Dates of Career Episode: A$st 7889 : Ma& 788; Geographical Location of the Experience Gained : San$rr< Pn=a*< -In!ia. Organisation Name: Pn=a* Porcelain Limite!< San$rr Title of Position : Plant En$ineer >AC24RO6ND This career episode includes the plant engineering work and duties performed in the production and operations of Punjab Porcelain Ltd, an S! "##$, %&'()& *('T)S and &+)S certi,ed, S- .roup /Sangrur ndustrial -orporation0 -ompan1 which manufactures and supplies Porcelain nsulators up to 23 +*, pin and post insulators, 4T and LT %ush nsulator for use in electricit1 transmission s1stem and Transformers5 completed m1 graduation in 6echanical (ngineering from Sant Longowal nstitute of (ngineering and Technolog1, Sangrur in 7##85 started looking for a job in mechanical engineering and with the assistance of one of the professors9 was able to initiate contact with the S- .roup, which was operating three manufacturing facilities in the cit1 outskirts5 was inter:iewed for Porcelain 6anufacturing ;acilit1 and after successful performance in the assessment9 started with the position of Plant (ngineer in the Punjab Porcelain Ltd5 directl1 worked with the Plant 6anager and Plant Super:isor, who guided me to gain through understanding of the plant production and operations5 Punjab Porcelain is pri:atel1 owned compan1 with multi state go:ernments and pri:ate transformer manufacturing companies as their ke1 clients5 The insulators /porcelain product0 manufacturing process <ow included raw material grinding and mi=ing in ball mill, agitator tanks, dewatering, ,ltering and cla1 cake forming in ,lter press, blank shaping in De>airing pug mill, blank shaping to insulators on manual machine, ,nal shaping, pre>dr1ing in hot room and under natural sunlight, dr1>,nishing on machine cutter, gla?ing /coating0, ,nal baking in shuttle kiln, sorting, electrical testing, assembling with metal parts, mechanical testing, packing, inspection and dispatch operations5 The plant production was in continuous and %atch mode depending upon the order and re@uirements and was the responsible plant engineer managing production, maintenance and engineering tasks on account of small si?e of the plant with the appro=imate capacit1 of 3# 6etric tonne production per month5 OR4ANISATION STR6CT6RE $5$ $57 Other Vendor/Contractors Other Vendor/Contractors Plant Manger/Director Plant Manger/Director Mechanical/Electrical /Civil Fitters Mechanical/Electrical /Civil Fitters Plant Engineer (Vikramjit Singh Aulakh Plant Engineer (Vikramjit Singh Aulakh Plant Su!ervisor Plant Su!ervisor Plant O!erators/"a#our Plant O!erators/"a#our Administration Administration PERSONAL EN4INEERIN4 ACTI1ITY nitiall1, during the induction period with the assistance of plant super:isor, went through the a:ailable plant documentation including process <ow chart, description of :arious process e@uipment and machiner1, testing and inspection facilit1 and roles and responsibilities of :arious personnel in the plant5 !n account of m1 keen interest and pre:ious e=perience gained during campus internships in the automobile components manufacturing operations, was able to relate to the production planning and control re@uirements5 4owe:er to understand the operations and design parameters of :arious e@uipments, studied the a:ailable information in the plant documents and then utili?ed the :arious :endorAs product information on the internet resources and ceramic industr1 handbook and plant engineering handbooks from the librar15 6oreo:er with the plant director support, was able to perform site :isits of other major production facilities in the state, which reinforced m1 technical understanding of the e@uipment operations5 n da1 to da1 operations, discussed and planned dail1 production targets considering the complete order and deli:er1 schedule, and in order to perform eBecti:e planning, used the .antt chart tool approach5 &sing the plant process block <ow diagram, calculated the loading at each of the machines and used the speci,c assetCmachine register to monitor the in>process production and $52 $58 $5D in:entor1 at each machine5 Since the block <ow diagram onl1 represented the process <ow rather than actual number of e@uipment, therefore prepared a detailed manual sketch of each t1pe and number of machines in the plant to perform e@uipment a:ailabilit1 studies corresponding to machine loading as per the ma=imum production re@uirements5 n this e=ercise, anal1sed the :arious scenarios and probabilities of a:ailabilit1 of the e@uipment and obser:ed that Shuttle +iln was the critical e@uipment in the conte=t of production se@uence and product @ualit1, the downtime of which directl1 caused loss of production and waste of the in> process products because we were operating the both shuttle kilns to ma=imise the production5 6oreo:er, the improper operation of the burners and hence the inappropriate temperature pro,le caused improper sintering and hence product failure in the @ualit1 assurance tests5 -oncerning these issues, brainstormed on the defect elimination methodolog1 and put forward together the plan to closel1 monitor the kiln process and operating parameters to in:estigate root cause5 discussed the approach with m1 super:isor, gathered his re:iew and charted>out the detail acti:ities for the operation parameters mapping and maintenance strateg15 commenced e=amining shuttle kiln details, estimated and assumed process heat balance and components capacities while managing the dail1 production coordination acti:ities5 The shuttle kiln si?e was appro= 8mE7m with si= burners installed on both side, and one blower to circulate the air and de:elop the pressure pro,le necessar1 for better product ,ring and sintering5 discussed the burner issues encountered with the ,re>man and the mechanical ,tter who attended the continuous operation and performed fre@uent o:erhauling and maintenance of kiln operational failures5 used the ;ailure 6ode (Bect )nal1sis /;6()0 framework to ,nd out each failure mode and corresponding root causes and defects causing the operation failure5 6oreo:er, established and prepared a register to continuousl1 monitor the operating parameters of shuttle kiln, which included temperature, blower pressure and pressure pro,le, and retention time inside the shuttle kiln b1 directl1 measuring the thermocouple and pressure gauges readings, and inlet and outlet pressures on the burner5 de:ised the diesel fuel consumption +Ps with relati:e to the production numbers so as to optimise the product loading and fuel consumption in the kiln5 The proacti:e continuous mapping of :ariations in +iln operational parameters and product rejection pro,le using statistical modeling pro:ided me the opportunit1 to measure process capabilit1 and impro:e the reliabilit1, a:ailabilit1 and maintainabilit1 of the shuttle kiln5 discussed the idea of pro:iding e=tra blower for the shuttle kilns as part of correcti:e actions, and worked on the no??le spare>part in:entor1 management strateg1, which was the critical on account of recurring issues with burners especiall1 for one of the shuttle kiln, which was more aged compared to the other5 The maintenance cost and rejection pro,le was continuousl1 increasing for that kiln and the refurbishment cost as per m1 cost bene,t anal1sis was @uite $53 $5F e=pensi:e5 n the coming months, we had a forced breakdown for that kiln and the management decided to use the parts from that kiln to use and increase the reliabilit1 of the other5 Therefore, prepared a refurbishment strateg1 and worked with our ,tters and specialist :endor representati:e to install the e=tra blower for the kiln in operation, which increased the reliabilit1 of the kiln5 regularl1 maintained asset register and pre:enti:e maintenance register for each e@uipment in the plant and recorded monthl1 audit and inspection results, and moti:ated the permanent staB ,tters to look proacti:el1 for inspection of especiall1 ke1 rotating e@uipments such as the ball mills, agitators, slurr1 pumps transferring the cla1 slurr1, diesel forwarding pumps to kiln burners5 ;or one of the three ball mills, Ge obser:ed fre@uent bearing failure while maintaining pre:enti:e maintenance, in order to resol:e that performed a root cause anal1sis using :arious bearing failure models and included plant super:isor and maintenance personnel in the discussion5 researched :arious bearing and ball mills failure modes using the :endor resources, research articles, and plant engineering and maintenance handbooks5 To troubleshoot and in:estigate the root cause matri=, worked with the maintenance ,tters, checked the ball mill loading and operation comparing with other ball mills, mapped the bearing failure pattern and damage, lubrication and greasing schedule, and checked the soft spot and shaft alignment, where had the reser:ations5 coordinated for an e=ternal contractor to check and correct the shaft alignment and kept close inspection track and resol:ed the issue ,nall15 also disseminated the theoretical knowledge to the maintenance staB in conte=t to the real issues which we faced5 diagnosed and troubleshoot :arious rotating e@uipments mechanical failures and recurring problems and recorded correcti:e action and ensured implementation of the maintenance work orders especiall1 for the cla1 forwarding and diesel forwarding pumps5 Ge fre@uentl1 faced problems with the cla1 slurr1 forwarding pump, speciall1 the reduced discharge <ow to the ,lter press5 performed pressure drop in:estigation calculations for the pump where used theoretical densit1 :alues with rheological data assumptions based on the particle si?ing and slurr1 mi=ture, static head directl1 measured, and d1namic head calculated using suction and discharge con,guration5 took assumptions on motor eHcienc1 and then calculated iterati:el1 relationships between the a:ailable power and pressure head to estimate for :arious operation conditions5 ;or most of times, performed mapping for the replacement fre@uenc1 for wearing of seals and bushes, and calculated mean time between failures to compare with the :endor recommendations to anal1se an1 defects5 proacti:el1 worked on :alue engineering initiati:es with e1e on reducing cost and impro:ing e@uipment functionalit15 kept track on the <uid and lubrication schedule for the machines, pumps and $5I $5" gearbo=es and ensured the oil cleanliness to reduce the wear inside the bearings5 Gith the guidance of plant super:isor and plant e=perience, produced the maintenance strategies for the rotating e@uipment and performed criticalit1 anal1sis to ,nd out critical spares and prepared a register to manage the in:entor1 of critical spares such as ball mill bearings, pumps mechanical seals and burner no??les so that parts a:ailabilit1 reduces e@uipment downtime in case of sudden failure5 Ghile working and super:ising mechanical and electrical ,tters, also worked on maintenance method statements so that in absence of ke1 ,tters, an1 e=ternal contractor shall be able to perform the work5 )s part of @ualit1 management plan, worked towards managing the documentation as per S! "### re@uirements, coordinated with the laborator1 as per the schedule for calibration of the instruments5 managed strong discipline on house>keeping eBorts and super:ised the staB to follow the e@uipment operating instructions in order to mitigate an1 ha?ards5 S6MMARY 61 role as a plant engineer in the Punjab Porcelain manufacturing operations pro:ided e=cellent production and operations support to deli:er the re@uired order with the @ualit1 assurance, and m1 approach towards asset management pa:ed the wa1 for more reliabilit1 and a:ailabilit1 of the e@uipments5 Signature of -andidate: -andidateAs *eri,erCs Details Name: )shok .o1al____________________________________________________________________ Phone? email: __________________________________________________________________ Position: Plant Director _______________________________________________________________________ Relationship to Can!i!ate: Direct super:isor _______________________________________________________ En$ineerin$ @ali)cations: ___________________ :erif1 that the abo:e narrati:e is a true account of the candidates own work5 Si$natre:______________________________________________________________________