Maintenance Optimization:Optimizing logic designs for Siemens PLCs and faults diagnosing including S7-400 and S7-300, utilizing CEMAT PCS7 V9.1 software and TIA Portal (versions V13, V15, V15.1, V16) for S7-1200, S7-1400, and S7-1500 Siemens PLCs and modification of logic for Siemens smart series S7-200 PLCS using Microwin Smart (V2.5) .Implementation DCS logics, control loops design, and HMI graphics design .Performing root cause analysis (RCA) entails investigating the fundamental factors behind equipment failures and executing corrective measures. This process involves scrutinizing program logic, validating input/output signals, assessing hardware configurations, and evaluating communication networks. Additionally, by monitoring system logs, alarm history, and process data, a significant reduction of 5% in equipment failures was achieved . Establishing a proactive maintenance schedule to prevent equipment failures. This encompasses routine inspections, calibration and the timely replacement of worn-out components in accordance with manufacturer guidelines and historical data analysis. As a result, a notable 15% decrease in downtime has been attained, along with optimized consumption of spare parts. Reviewing Documentation including Hookups, I/O list, trip and alarms summary, SAT, FAT, PFD, P&ID and control wiring diagrams. Implementing backup and recovery procedures for PLC programs to safeguard against data loss and ensure quick restoration in the event of failures, Developing a comprehensive calibration schedule based on the criticality of instruments, manufacturer recommendations, and regulatory requirements. Procurement and inventory management of all control system equipment using Lucky Enterprise Resource Planning (ERP) system and System Application and Products (SAP S/4 Hana).

Project (New Line II 9000 TPD) Responsibilities: Led the installation of a 9000 TPD cement production line on time and within budget, ensuring exceptional project execution. Siemens PLC panel designed by SINOMA configured for cement manufacturing encompasses stages from raw material grinding to packing, utilizing communication protocols like EtherNet/IP, PROFINET, Profibus DP, and Optical Fiber. Utilized Siemens PLC S7-400 and programming software CEMAT PCS7 V9.1 included SIMATIC MNAGER V5.7 to develop PLC logic and control algorithms, and WINCC HMI for monitoring control operations by operators.Interfaced diverse sensors such as RTDs, Thermocouples, Vibrometer, Proximity switches, Pressure Transmitter, Actuators, and Gas Analyzer with PLC for real Data Aquisition and monitoring critical control parameters ensuring efficient and reliable operation while optimizing production performance and maintaining product quality standards. Configuration of communication protocols (e.g; Profibus, Profinet) to establish seamless data exchange between PLCs and peripheral devices such as MCUs, VFDs, Scheck Motor etc.I led as commissioning with Chinese team of SINOMA Company expert in control and automation DCS system ensured smooth and reliable operation of plant/ Provided technical support and training to plant personnel on PLC operation, troubleshooting, and maintenance procedures, fostering a culture of continuous improvement and knowledge sharing.

As a Robotics Lab Engineer at Punjab Group of Colleges my role was instructing students on robotics concepts, programming, and practical applications. Led to facilitate hands-on learning experiences, fostering innovation and problem-solving skills among students in the field of robotics.PROJECT: Path Planning and Obstacle Avoidance Based Mobile RobotThis project involves the development of a mobile robot equipped with Arduino microcontrollers for path planning and obstacle avoidance capabilities. The robot is designed to autonomously navigate through an environment while avoiding obstacles in its path.The robot uses data from the ultrasonic sensors to detect obstacles in its path. When an obstacle is detected, the Arduino executes an obstacle avoidance algorithm to navigate around the obstacle while staying on the planned path. This may involve adjusting the robot's trajectory or stopping and re-routing.By combining Arduino microcontrollers with sensors and actuators, this project demonstrates an effective solution for autonomous navigation in mobile robots. The path planning and obstacle avoidance capabilities enable the robot to safely navigate complex environments, making it suitable for applications such as indoor navigation.

Project: Mobile Robot Navigation System