Satish Kumar

Experience

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  Prolec GE

  Dec 2007 - Dec 2014

  PROLEC – GE Distribution Transformer plant Thirumazhisai, Tamil Nadu, India.• Coordinating with purchase, logistics, stores for sending materials to job work Contractors• Maintaining the list of all material sent and received for each contractor's • Getting jobs from all contractors on time for in house production requirement• Conducting Quality check and Maintaining stock of materials in contractor end• Auditing vendor site for Reconciliation of materials Sent, Received, consumed and Balance• Forwarding Bills to finance for payment by checking material receipts Show less PROLEC - GE (Indo Tech Transformer) Chennai IndiaManufacturing of Large Power Transformer Up to 180 MVA 400 KV Class Transformer• Daily process audit in winding, Sizing, Insulation and display the Observation in Metric Board. • Implement Corrective actions from Audit observation with help of Operators and supervisors• Prepare subordinate drawing for winding insulation• Prepare shop floor TPS metrics like cycle time, Output per shift, Operators output, Process audit , • Communicating design errors to designers and suggesting corrective and call preventive actions• Conducting TPS Work shop weekly in winding, sizing, Insulation and assembly shop • Improve productivity through Brainstorming and implement 5 Kaizens weekly to reduce 7 wastes.• Updating the operator quality & training records Show less Career Accomplishments• Implemented 190 kaizen to improve 5s, Quality, Productivity, And Reduce cost, Movement, Waiting, Rework in the area of winding and coil assembly.• Reduction of winding failure to Zero in last 4 years. Provided training to Supervisors, Instructors and Operators.• Cash price for most number of kaizen in Q1 2012 & Best Kaizen in Q4 2012 in winding and Sizing• Loaded 3 coils in parallel instead of 2 coils in former and achieved 20% reduction of cycle time.• Completed a project single helical winding manufacturing using disc guide and pre transposition. It saves 35% of cycle time.• Re Introduced the short method to check coils shorting between parallel conductors • Suggest designing to buy Copper in length instead of weight and solid insulation instead of conventional practice to Save scrap generation of 6% .• Cost reduction of heat run test in test lab by optimum using of DG saves 2 Lakhs/Annum• Changed the purchasing of Kraft paper insulation used for distribution transformer winding width and reduced the wastage of 15% which saves 1.5 Lakh/ Annum• Made a Excel sheet to create Ride over and packing strip required for coil winding and shared with Design to implemented which reduce the insulation material wastage.• Modified the winding checklist to one page from 5 page of Mexico Checklist • Formulated Methods for different types of winding and Coil Assembly• Optimum using of winding m/c and Auto Clave to save the production cost Show less

  • Project Coordinator for 100 & 250 KVA Core Coil Assembly (Managed Position)

    Jul 2014 - Dec 2014

  • Process Engineer in Winding, Coil assembly & Insulation - Upto 180 MVA, 400 KV

    Jan 2014 - Jun 2014

  • Production (Operation) Engineer - Winding, Pre Coil Assembly, Insulation - Upto 180 MVA, 400 KV

    Dec 2007 - Dec 2013
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  CSE Power

  Jan 2015 - Aug 2016

  Engineer - Testing and Process Improvement - LT transformer. inductor.

  • Implemented kaizen to eliminate 7- type of waste in process and improve process efficiency, • Time study, process audit, 5S audit, - In the area of coil, core-coil assembly, varnishing, testing.• Cost and time reduction projects in shop floor activities • Trained testing team to analysis testing failure by root cause analysis method• Reported - Monthly KPI, testing failure RC, six-sigma analysis in Minitab.

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  KAPPA ELECTRICALS PRIVATE LIMITED

  Sept 2016 - Sept 2017

  Assistant Production Manager- CT, PT

  • Trained new operators and minimized testing rejections to zero.• Pushed jobs in all stages like material purchase, core preparation, winding, die fitting, casting, finishing, testing, dispatch packing.• Troubleshooting resin cast Instrument transformer failures and rectified by CA & PA • Achieved 100% of monthly sales target in LVCT production

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  DEUTSCHLAND TRANSFORMERS PVT. LTD

  Oct 2017 - Sept 2018

  Senior Engineer Production - Dry type transformer, CT, PT

  • Plan and execute production of dry type transformer.• Coordinated with Central power research institute for CT & PT testing & witness the test.• Initiated tender participation and offer preparation, digital marketing of company products sales 25%• Involved in development of Casting Die, New Product sourcing, New Customer base 20%• Site visit for physical inspection of CT & PT to make new CT & PT to adopt in existing place

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  Qatar General Electricity & Water Corporation (Kahramaa)

  Sept 2018 - Feb 2022

  Project Engineer - Transformer maintenance & Repair

  • Check the transformer physically at client premises; coordinate logistics • Transformer Maintenance report & record keeping (Initial inspection, In-process, final inspection report)• Co-ordinated with Qatar Electricity board for material, issuance and delivery of transformers• Strengthened leak identification by trained technicians and eliminated major leak during final inspection • Erection and commissioning of 1600 kVA Transformers at customer site.• Maintenance of 5 different Makes of transformers such as Voltamp, federal, Emirates, Utec,& Matelec transformers Show less

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  AYT International Group

  Feb 2022 - Oct 2022

  Testing and commissioning engineer
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  Korica u ltd

  Dec 2022 - now

  Production Manager

  Distribution transformer