Prangya Mishra

Using computer vision to track movement of a complex conveyor line in auto manufacturing plant and minimise throughput loss of the line

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IoT based extrusion management system for a large Aluminium extrusion company. This is a MES for extrusion plant built using a modern IoT platform

The solution owner and architect for developing connected Aluminium downstream platform using Industrial IoT, Edge Computing and Data Lake technologies for one of the largest Aluminium producer in the world .

The solution owner and architect for delivering connected CNC machine Programe for a PSU company in India. The objective is to use Industrial IoT platform ( ThingWorx ) and leverage streaming Analytics to improve operational excellence.

ThingWorx Industrial IoT Implementation for Operational Improvement.

Tracking of (container based) consignments mid sea without using any GPS device on actual containers being tracked. The tracking information is continuously being fed into SAP for further downstream activities ( customer services including). This is made possible using big data.

This is a MES (Ampla) Application outsourcing (aka ADM) project for one of the global mining company for their coal mine operations. The scope of the service is spread accross four different instances of Ampla system for incident management, regular MACs related to Ampla system apart from undertaking change requests and projects, typically provding L2 and L3 support.

* The project is for automatic cut height measurement & contextualization using OSISoft PI and Ampla for Long wall method of under ground coal mining for a top 5 global mining company.
* Cut height measurement is essential to understand the "dilution" factor for under ground coal mining.
* Out come of the project is more accurate, automated and real time visibility into plan vs.actual cut height for long wall method of coal mining.

This project was carried out as a part of the "operational improvement" for above ground and under ground coal mine of a global mining company for it's Australian operations. I worked as the solution architect for EWS (Exchange Web Services) based integration to connect the 3rd party external lab LIMS system with client's MES (Ampla) instances.
The objective of the project was to ultimately connect site SCADA to external lab's LIMS system and download the lab analysis onto site SCADA… Mehr zeigen

This project was carried out as a part of the "operational improvement" for above ground and under ground coal mine of a global mining company for it's Australian operations. I worked as the solution architect for EWS (Exchange Web Services) based integration to connect the 3rd party external lab LIMS system with client's MES (Ampla) instances.
The objective of the project was to ultimately connect site SCADA to external lab's LIMS system and download the lab analysis onto site SCADA (Citect) system through Ampla and OSISoft PI so that operators can take real time decission to control / manage the process parameters accordingly. Weniger anzeigen

*Upgrade planning and project management.
* Business Analysis and Design of new requirements to be incorporated pre and post upgrade.
*Leading the team to undertake the upgrade from existing vesion 4.2 to 6.0
*Modernization of existing application build around Ampla.

* Project co-ordinator and SME for Honeywell PHD to OSI PI Migration project for a mining client.
* Responsible for day to day planning activities and ensuring the project is on track,FAT and UAT support
* Help the team to resolve technical issues with the migration work

* Conceptualized the patent granted idea of SMAPP.
* Architect the Ux for the prototype.

The PoC project was intended to showcase the capabilities of Ampla, Schneider Electric's MES product as a analytical and suplimentary tool for cold rolling mill management system.

*Proof of Concept developed to showcase the capability of Schneider Electric MES product "Ampla" for secondary steel processing lines such as Continuous Galvanizing Line (CGL).
*Ampla modules considered as a part of the PoC are Production, Planning and Recipe, Inventory, Quality, Downtime, Maintenance and Metrics.

*MES implementation for one of the top Aluminium producers of the world.
*Implemented MES for Aluminium Smelter (Potline).
* Worked as a Subject Matter Expert and functional consultant for Schneider Electric MES Product "Ampla".
*Ampla modules implemented : Production,Downtime,Quality,Maintenance,Metrics,Inventory and Planning.

Converting the Raw Plant data into useful Business Information. Real Time scenario of the plant process and the operation using dashboards and analytics. Process improvement and asset performance improvement using continuous escalation of exceptions to the shop floor personnel and their superiors.
MES implementation in the Pot line which helps in enhancing the purity of the hot metal by providing real time results of the quality sampling and blending of the pots.
Tranparent system at the… Mehr zeigen

Converting the Raw Plant data into useful Business Information. Real Time scenario of the plant process and the operation using dashboards and analytics. Process improvement and asset performance improvement using continuous escalation of exceptions to the shop floor personnel and their superiors.
MES implementation in the Pot line which helps in enhancing the purity of the hot metal by providing real time results of the quality sampling and blending of the pots.
Tranparent system at the cast house which helps in reduction of the rejects and hence enhancing the customer satisfaction.
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* Business Process Blue printing for MES implementation for one of the top 6 steel producers in the world.
*Business Process Blue printing for one of the top miners in the world for global MES roll out.
* Worked as lead from off shore delivery center for the blue printing process.

Real time Integration of SAP-PP module with MES.

* Worked as lead functional designer from Essar Steel for implementation of MES.
* This is a customized MES solution designed by Essar Steel in association with technology partner ATPL , Pune.
*Modules implemented : Production , Quality , Inventory and APS.
*Feature : Real time integration with SAP using PI , auto scheduling and it's integration with JDA S&OP , Cross plant production planning and optimization.

Project Details:
Leading producer of metallurgical grade alumina and other aluminium products
Project involves integration of shop floor field devices to MES and integration of MES to SAP (Level I to Level IV integration).
Role: Manufacturing Domain Specialist, Project Manager for MES Implementation & Integration Manager for integrating MES to SAP through SAP MII Module.
Responsibilities:
Leading the Requirements Gathering workshops for MES, Integration of MES to SAP and… Mehr zeigen

Project Details:
Leading producer of metallurgical grade alumina and other aluminium products
Project involves integration of shop floor field devices to MES and integration of MES to SAP (Level I to Level IV integration).
Role: Manufacturing Domain Specialist, Project Manager for MES Implementation & Integration Manager for integrating MES to SAP through SAP MII Module.
Responsibilities:
Leading the Requirements Gathering workshops for MES, Integration of MES to SAP and Dashboards/Reports.
Analysis of requirements and mapping the customer requirements to MES modules.
Inputs to MES Technical team in preparation of GPO document for MES configuration.
Design & Development of Interfaces through MII for MES to SAP Integration. This includes Interfaces for Repetitive Manufacturing, Process Order & Production Order Scenario’s.
Unit Testing, Integration Testing & User Acceptance testing of the developed Interface programs
Developed Custom Applications in MII for End User. This includes the complete Maintenance cycle from Notification Creation to Order Closure, executed through MII screens to SAP. Also Notification Creation based on MES requests from WEB Services into SAP.
Standalone Application Developed in MII for Smelter Operations & Maintenance with Dynamic problem display screen
Developed Real time Smelting Pot status by Interfacing Control System based on Pot Controller signals.
Developed real time dashboard for Work Schedule compliance for Smelter Pots based on MES status by polling dynamic data from MES Web Services.
Developed application in MII for Quality clearance of Raw materials into SAP through MII Screens.
Developed application in MII for Maintenance cycle execution into SAP through MII screen.
Data mapping done for interface developments for integrating MES to SAP through SAP MII Module
Business Blue Print for integration of MES to SAP through SAP MII module.
Deployment & Go Live for Integration of MES to SAP, Dashboards and Reports.

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This project was undertaken as a part of six sigma green belt certification.The objective of the project was to improve the roll utilization in Hot Strip Mill by increasing the kilo meters rolled by the work rolls before getting changed.This required re-engineering to standard operating procedures (SOPs) of the Hot Strip Mill along with changes in scheduling patterns and also considering the techno economical aspects of Hot Rolling.

*Worked as team member for validating the business flow , scheduling and business logic built in the system, involved in FAT.
*One of the few implementation of MES for integrated steel plant in India.

The software was used to calculate the planned cost associated with production of galvanized coils.It endorsed other features such as finding out the best possible process route for the galvanized coil, comparison between different production orders and forecasting the profitability for the month based on order book, what if analysis of the costing for the month.