Muhammad Bilal

Experience

• 

  MEPCO - Multan Electric Power Company Ltd

  Jun 2017 - Jul 2017

  Internship Trainee

  • Inspected the operation of the 220 kV substation and its control room.• Learned about power-factor compensation techniques.• Reviewed the AC power scheme and real-time energy metering.• Learned the mechanism of electricity bill generation standardized by the National Electric Power Regulatory Authority (NEPRA).• Developed and modified an Electrical Power System by designing and simulating on ETAP software.

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  Volka Food International (Pvt.) Ltd

  Nov 2018 - Jan 2023

  Responsibilities:• Led a team of 16 professionals, including engineers and technicians, ensuring efficient operations and skill development.• Troubleshoot system faults and malfunctions in processing plants, wrapping and packing lines and machines.• Interpret electrical wiring diagrams (single line and schematic diagrams) for system analysis and workflow.• Diagnosing and resolving PLC & HMI hardware, software, and communication faults.• Conducting root cause analysis (RCA) of recurring process failures and implementing corrective actions.• Maintaining the PLC, HMI and VFD backup of machines and plants.• Analysing analyze open-loop, closed-loop and PID control systems.• Ensuring Environmental Health & Safety (EHS) compliance before initiating Permit-to-Work (PTW) activities.Projects:• Operational Continuity: System Restoration and HMI Cloning for the Chocolate Ball Mill PlantRetrieved runtime files from a malfunctioning hard drive of the PC-based HMI, cloned the system onto a new PC by installing the Siemens WinCC Flexible 2008 SP3 (a smaller stand-alone SCADA system) and configured the network settings (Modbus TCP/IP communication protocol) to ensure operational continuity.• Automation System Design and Integration: PLC and HMI Integration for Bubble Wrapping OperationDesigned and integrated the PLC and HMI system, mapping the digital and analog I/Os with Siemens S7-1200 PLC, Simatic TP700 HMI and Sinamics G120 VFD with Profinet communication, enabling precise control and automation.• Automation System Design & Integration: PLC and HMI Integration for Biscuit Moulder OperationDesigned and integrated the PLC program and HMI interface with VFD control, utilizing the Fatek FBs-40MC and Weintek MT-8071iE HMI through Modbus RS-485 serial communication protocol to optimize the operation and monitoring. Show less Responsibilities:• Troubleshoot and performed corrective maintenance of electrical installations for confectionery and bakery plants and wrapping and packing lines.• Commissioning, testing, and fault diagnosis of motor starter circuits, soft starters, VFDs and servo drives.• Dealt with parameterization and commissioning of various VFDs, including Sinamics V20 & G120, PowerFlex 525 & 753, Danfoss VLT FC51, FC301, FC302 & 2800, Schneider Altivar ATV310 & 312 and INVT CHF100A.• Conducted calibration of instrumentation devices using different calibrators such as Emerson 475 Field Communicator and Druck DPI 611.• Designed, modified, integrated, and implemented industrial automation and control systems.Gained extensive hands-on experience experience with PLCs; Siemens S7-200/300/1200/1500, Delta, Fatek, Allen-Bradley and Mitsubishi and HMIs such as Simatic, PanelView Plus, Weintek and Delta.• Proficient in Ladder Logic (LD) programming with a strong understanding• Programmed PLCs using Ladder Logic (LD) language and developed a strong understanding of Function Block Diagrams (FBD)• Developed proficient understanding of industrial communication protocols such as Modbus, Profinet, Profibus, EtherNet/IP and HART.Projects:• Conventional to PLC: Design and Upgradation of Control Architecture for Biscuit Packing MachineUpgrading the traditional control architecture to a PLC and HMI configuration, utilizing the Delta DVP 20SX2 PLC and Delta DOP-107DV HMI with Modbus RS-485 serial communication to improve operational performance.• Automation System Integration: Automated Cooling System for Chocolate-Filled Toffee ProductionEngineered and implemented an automated cooling system by configuring digital and analog I/O interfaces with the Siemens S7-300 PLC, Simatic KTP400 HMI and Sinamics G120 VFD through Profibus communication protocol. Show less Responsibilities• Planned, scheduled, and executed preventive maintenance activities for confectionery and bakery plants, as well as wrapping and packing machines, in coordination with the production team, ensuring maintenance KPIs such as downtime, MTTR, and MTBF were achieved• Designed and modified control logic utilizing electrical and instrument components such as push buttons, limit switches, relays, magnetic contactors, circuit breakers, sensors, thermocouples, RTD Pt100, transducers, transmitters, flow meters, load cells, encoders, resolvers, solenoid-operated valves (SOV), control valves, actuators, etc.Projects:• Jelly Plant Installation and Commissioning (WDS, Germany):Installed and commissioned all major sections of the jelly plant, including the kitchen, starch drying, color-flavor-acid mixing, stamping, and depositing areas. Worked on equipment like mixers, holding tanks, cookers, conveyors, depositors, demolders, and drying rooms.• Biscuit Plant Installation and Commissioning (Imaforni, Italy):Installed and commissioned the moulder, wire-cut section, oven, stacker, and packing lines. Adjusted burner settings to meet operational needs.• SAP S/4HANA Plant Maintenance Module Implementation:Played a pivotal role in the successful implementation of the SAP S/4HANA PM module by collecting data for machines and plant equipment. This included creating an inventory of electrical items, defining locations for cost tracking, and setting reorder points to automate material requests. Show less

  • E&I Engineer

    Dec 2021 - Jan 2023

  • Junior E&I Engineer

    Nov 2019 - Nov 2021

  • Trainee E&I Engineer

    Nov 2018 - Nov 2019
• 

  EBM

  Jan 2023 - Sept 2023

  Team Lead E&I

  Responsibilities:• Planned, scheduled, and executed preventive maintenance activities in coordination with the production department.• Ensuring compliance with the maintenance KPIs, including minimizing downtime, reducing MTTR and improving MTBF.• Troubleshoot system faults and malfunctions in processing plants, wrapping and packing lines and machines.• Diagnosing and resolving PLC & HMI hardware, software, and communication faults.• Performing the root cause analysis (RCA) for repeating process failures and implementing solutions.• Maintaining the PLC, HMI and VFD backup of machines and plants.• Managing notifications, work orders, downtime, inventory and requisitions using the SAP Plant Maintenance module.• Ensuring Environmental Health & Safety (EHS) compliance before initiating Permit-to-Work (PTW) activities.• Collaborating with OEMs, contractors and stakeholders for system rectifications, modifications and improvements.• Led a team of 21 professionals, including engineers and technicians, ensuring efficient operations and skill development. Show less

• 

  KCA Deutag

  Sept 2023 - Sept 2024

  Field Service Engineer

  Responsibilities:• Troubleshoot rig electrical systems, including Top Drive and VFD house (Canrig) to ensure optimal functionality.• Collaborate with the electrical supervisor on fault analysis reports and coordinate with the electrical team to oversee repairs.• Maintain backups for critical rig equipment, including PLCs and VFDs, to facilitate prompt recovery from system failures.

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  Confidential

  Sept 2024 - now

  Automation Engineer