Career_Episode_Report1.doc

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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"ema!e claims ofac#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 inAstralia 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 ofImmi$ration an! Citi,enship -DIAC. for inte$rit& chec(in$/0%

Printed Name : 1I2RAM3IT SIN45 A6LA25

Signature : _________________________

Date : _________________________

Career Episode Report 1- Vikra!it Si"#$ A%&ak$ 'a#e 1 o( )


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Career Episode 1Punjab 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*AC24RO6NDThis career episode includes the plant engineering work and dutiesperformed in the production and operations of Punjab Porcelain Ltd,an S! "##$, %&'()& *('T)S and &+)S certied, S- .roup/Sangrur ndustrial -orporation0 -ompan1 which manufactures andsupplies Porcelain nsulators up to 23 +*, pin and post insulators,

4T and LT %ush nsulator for use in electricit1 transmission s1stemand Transformers5 completed m1 graduation in 6echanical(ngineering from Sant Longowal nstitute of (ngineering and

Technolog1, Sangrur in 7##85 started looking for a job inmechanical engineering and with the assistance of one of theprofessors9 was able to initiate contact with the S- .roup, whichwas operating three manufacturing facilities in the cit1 outskirts5 was interiewed for Porcelain 6anufacturing ;acilit1 and aftersuccessful performance in the assessment9 started with theposition of Plant (ngineer in the Punjab Porcelain Ltd5 directl1

worked with the Plant 6anager and Plant Superisor, who guidedme to gain through understanding of the plant production andoperations5 Punjab Porcelain is priatel1 owned compan1 with multistate goernments and priate transformer manufacturingcompanies as their ke1 clients5

The insulators /porcelain product0 manufacturing process airing pug mill, blank shaping to insulators onmanual 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, assemblingwith metal parts, mechanical testing, packing, inspection anddispatch operations5 The plant production was in continuous and%atch mode depending upon the order and re@uirements and wasthe responsible plant engineer managing production, maintenanceand engineering tasks on account of small si?e of the plant with theappro=imate capacit1 of 3# 6etric tonne production per month5

OR4ANISATION STR6CT6RE

$5$

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Other

Vendor/Contractors

Plant

Manger/Director

Mechanical/Electrical

/Civil Fitters

Plant Engineer

(Vikramjit Singh

Aulakh

Plant Su!ervisor

Plant

O!erators/"a#ourAdministration

PERSONAL EN4INEERIN4 ACTI1ITY

nitiall1, during the induction period with the assistance of plantsuperisor, went through the aailable plant documentationincluding process


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inentor1 at each machine5 Since the block out the detail actiitiesfor the operation parameters mapping and maintenance strateg15

commenced e=amining shuttle kiln details, estimated andassumed process heat balance and components capacities whilemanaging the dail1 production coordination actiities5 The shuttlekiln si?e was appro= 8mE7m with si= burners installed on both side,and one blower to circulate the air and deelop the pressure prolenecessar1 for better product ring and sintering5 discussed theburner issues encountered with the re>man and the mechanical

tter who attended the continuous operation and performedfre@uent oerhauling and maintenance of kiln operational failures5 used the ;ailure 6ode (Bect )nal1sis /;6()0 framework to nd outeach failure mode and corresponding root causes and defectscausing the operation failure5 6oreoer, established and prepareda register to continuousl1 monitor the operating parameters ofshuttle kiln, which included temperature, blower pressure andpressure prole, and retention time inside the shuttle kiln b1directl1 measuring the thermocouple and pressure gaugesreadings, and inlet and outlet pressures on the burner5 deisedthe diesel fuel consumption +Ps with relatie to the productionnumbers so as to optimise the product loading and fuelconsumption in the kiln5 The proactie continuous mapping ofariations in +iln operational parameters and product rejectionprole using statistical modeling proided me the opportunit1 tomeasure process capabilit1 and improe the reliabilit1, aailabilit1and maintainabilit1 of the shuttle kiln5 discussed the idea ofproiding e=tra blower for the shuttle kilns as part of correctieactions, and worked on the no??le spare>part inentor1management strateg1, which was the critical on account ofrecurring issues with burners especiall1 for one of the shuttle kiln,

which was more aged compared to the other5 The maintenance costand rejection prole was continuousl1 increasing for that kiln andthe refurbishment cost as per m1 cost benet anal1sis was @uite

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e=pensie5 n the coming months, we had a forced breakdown forthat kiln and the management decided to use the parts from thatkiln to use and increase the reliabilit1 of the other5 Therefore, prepared a refurbishment strateg1 and worked with our tters andspecialist endor representatie to install the e=tra blower for thekiln in operation, which increased the reliabilit1 of the kiln5

regularl1 maintained asset register and preentie maintenanceregister for each e@uipment in the plant and recorded monthl1audit and inspection results, and motiated the permanent staBtters to look proactiel1 for inspection of especiall1 ke1 rotatinge@uipments such as the ball mills, agitators, slurr1 pumpstransferring the cla1 slurr1, diesel forwarding pumps to kilnburners5 ;or one of the three ball mills, Ge obsered fre@uentbearing failure while maintaining preentie maintenance, in orderto resole that performed a root cause anal1sis using ariousbearing failure models and included plant superisor and

maintenance personnel in the discussion5 researched ariousbearing and ball mills failure modes using the endor resources,research articles, and plant engineering and maintenancehandbooks5 To troubleshoot and inestigate the root cause matri=, worked with the maintenance tters, checked the ball mill loadingand operation comparing with other ball mills, mapped the bearingfailure pattern and damage, lubrication and greasing schedule, andchecked the soft spot and shaft alignment, where had thereserations5 coordinated for an e=ternal contractor to check andcorrect the shaft alignment and kept close inspection track andresoled the issue nall15 also disseminated the theoretical

knowledge to the maintenance staB in conte=t to the real issueswhich we faced5

diagnosed and troubleshoot arious rotating e@uipmentsmechanical failures and recurring problems and recorded correctieaction and ensured implementation of the maintenance workorders especiall1 for the cla1 forwarding and diesel forwardingpumps5 Ge fre@uentl1 faced problems with the cla1 slurr1forwarding pump, speciall1 the reduced discharge


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gearbo=es and ensured the oil cleanliness to reduce the wear insidethe bearings5 Gith the guidance of plant superisor and plante=perience, produced the maintenance strategies for the rotatinge@uipment and performed criticalit1 anal1sis to nd out criticalspares and prepared a register to manage the inentor1 of criticalspares such as ball mill bearings, pumps mechanical seals andburner no??les so that parts aailabilit1 reduces e@uipment

downtime in case of sudden failure5 Ghile working and superisingmechanical and electrical tters, also worked on maintenancemethod statements so that in absence of ke1 tters, an1 e=ternalcontractor shall be able to perform the work5 )s part of @ualit1management plan, worked towards managing the documentationas per S! "### re@uirements, coordinated with the laborator1 asper the schedule for calibration of the instruments5 managedstrong discipline on house>keeping eBorts and superised the staBto follow the e@uipment operating instructions in order to mitigatean1 ha?ards5

S6MMARY61 role as a plant engineer in the Punjab Porcelain manufacturingoperations proided e=cellent production and operations support todelier the re@uired order with the @ualit1 assurance, and m1approach towards asset management paed the wa1 for morereliabilit1 and aailabilit1 of the e@uipments5

Signature of -andidate:

-andidateAs *erierCs Details

Name: )shok.o1al____________________________________________________________________

Phone? email:

__________________________________________________________________

Position:Plant Director

_______________________________________________________________________

Relationship to Can!i!ate: Direct superisor

_______________________________________________________

En$ineerin$ @ali)cations:___________________

erif1 that the aboe narratie is a true account of the candidates own work5

Si$natre:______________________________________________________________________

Documents

Career_Episode_Report1.doc