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Engineer Quality

Location:
India
Salary:
40lacs per annum
Posted:
February 07, 2016

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Resume:

NAVASAKTHI MUNIYASAMY

email: actfk8@r.postjobfree.com

+91-979*******

+91-960*******

OBJECTIVE:

I have over 22 years of experience in the DUCTILE IRON, GREY IRON FOUNDRY & STEELMAKING MANUFACTURING INDUSTRY (Billets/Ingots/Reinforcement bars or Rebar/casting) as related Metallurgy, QA/QC,Production & Planning Field.

Areas of Expertise:

Manufacture of Ductile iron, Grey iron, Compacted graphite (Vermicular) iron, Ni-hard, Ni-resist, Stainless Steel, Cu-Bronze, Aluminum - Non-Ferrous & Ferrous Foundry by No-bake (Furan ) & green sand system (DISA) For Automobile, Earth Moving, Wind Mill, Pump, Valve, Hydraulic components and Textile Components

Manufacture of Steel Billets, Ingots, Hi-Tensile Reinforcement Steel (TMT) Bar- & Flat and Angle

The operation of the following furnaces (Inductotherm, ABB & Ottojunker medium and High Frequency furnaces)

Rolling Mill & Section Mill process control, Billet/Ingot weight calculation for required size (TMT) re-bar manufacturing, Re-Heating Furnace, CCM & AOD, Hot-Charging process

Billets, Ingot selection for suitable Size of TMT Bars / Flat, Angle Section to eliminate random waste by calculation

Foundry process control, Material standards, Pattern and quality assessment systems.

Green Sand Mould, Co2 process, Shell Mould, No-Bake (Furan-Resin) Mould, Oil Core, Co2 Core, Shell Core, Cold box Core and Coating control for Mould & Core

Metallurgical, Micro Structure Analysis, Material Testing, Establishing processes using respective equipment Hardness, Tensile Testing, Impact Testing, Bend,re-bend Testing,NDT,Optical Emission Spectrometer (Metal Analyser) & Incoming Raw material Quality Inspection.

Moulding and preparing Production plan based on Daily, weekly & Monthly

In process and Final Inspection of castings based on international standards.

FMEA, APQP, PPAP & Updated and Review the PPAP Document (PSW, PIN, PFD, CP, FMEA), SOP & QCI / Six Sigma, 7QC Tools, Kaizen and 5S

Expertise in handling projects for improving quality reliability and cost reduction using available resources as per requirements.

Proficiency in the implementation of various Quality System & Technology Standards like TS16949, ISO 9001, 14000 and Customer Requirement of Specification.

Process Development and New Material Development as per customer requirement

Monitoring Production and Dispatch & Foundry and Machine shop rejection on Daily, weekly & Monthly basis, Conduct Rejection Analysis, Corrective and Preventive Action for Internal and Customer complaint

Monitoring and conduct the Calibration for quality instruments

Strong analytical skills with Metallurgical, Heat Treatment Process (Annealing, Normalizing and Stress relieving).

Evaluation and conduct the Employee training to improve the individual skill matrix

Evaluation of Raw Materials supplier capabilities and sub-contractors capabilities.

Conduct the Internal Audit as per schedule & Being able to audit new suppliers.

Summary of Experience: 22 Years

Having Overall Twenty Two (22) years of work experience

(Saudi Arabia/Africa–Gongo,Rwanda,Mali,Gabon,Angola/India)

Overseas Experience: 8 years

July 2014 – Till working as a SENOIR MANAGER QUALITY

FAMECO Group of Company, Kinshasa- Congo, Rwanda, Mali, Gabon & Angola- Africa, company manufactures High Tensile Reinforcement TMT Steel Bars, Bar Size 6,8,10,12,14,16,20,25,32 & 40mm & FLAT Size 20x3,30x3,40x3 & 50x3 and ANGLES 20x20x3, 25x25x3,30x30x3,40x40x3 & 50x50x3 by CCM & AOD Process & It is an ISO 9001-2008 certified company.

Technical and Executive Duties Responsibilities:

Rolling Mill & Section Mill process control, CCM Billet/Ingot weight calculation for required size (TMT) re-bar manufacturing

Billets, Ingot selection for suitable Size of TMT Bars / Flat, Angle Section to eliminate random waste by calculation

Implementing Policies,Objectives,strategies and Accredited work plans

Manages implementation of company quality policies, goals and strategies

Develops and sets the quality assurance procedures and determines quality requirements and guidelines.

Researching and probing customer complaints regarding the quality of services, reports and systems and the timely conduct, analysing the causes of such complaints.

Ensures corrective and preventive actions are implemented to reduce and overcome low standards of performance.

Arrange with section heads and quality engineers for all quality control activities.

Reporting to top management of system performance and any need for improvement.

Co-ordination and implementation of QMS as per ISO-9001-2008 system activity in the plant.

Ensuring the process needed for quality management system are identified and established.

Ensuring the customer requirements are fully understood within the organization by conducting orientation class.

Training the staff of the organization on quality management system, awareness on ISO-9001-2008, national and international material standards.

Making plan and schedule of internal audits and arranging audits as per schedule.

To co-ordinate and review the corrective and preventive action as decided in management review meeting, internal and external audits

Nov 2007 – May 2014 working as a Senior Metallurgist / Quality Control Engineer in M/S Saudi Mechanical Industries Co - Precision Casting Foundry, Riyadh, Saudi Arabia,the company manufactures Ductile Iron, Grey Iron, Stainless steel, Bronze, Ni-Al-Bronze and Si-Bronze, Vertical Line shaft Pumps, Vertical Turbine Submersible Pumps, Right Angle, Gear Drives, Round steel stainless steel Bars, Threaded Column Pipe, Continuous Cast, Bronze Bar, Porcelain Enamelling and Engineered Product & It is an ISO 9001-2008 certified company.

Technical and Executive Duties Responsibilities:

Material Testing and Analysis

Responsible for all Incoming Raw Material, Melting, Laboratory and QC Activities

Responsible for Moulding, Production plan for daily, weekly and Monthly

Metal preparation as per charge calculation to required specification ( Ductile, Grey, Ni-Hard, Ni-Resist, steel)

Metallographic, Hardness, Tensile, Impact Testing including sub-zero temperature to as per standard & NDT Testing.

Furan No-Bake sand control- sand Compression, strength, Impact penetration strength,sand LOI, AFS, Monitoring Sand temperature, Addition rate of % Resin, Fast catalyst, slow catalyst, New sand & Reclaim sand.

Responsible for Green Sand control for DISA SYSTEM

Responsible for Coating control - Mould graphite flood coating, Core Coating (Tenosil, Rheotech, Zircon, and Ceramal) viscosity Baume and solid content.

Initial sample casting Development

Spectrometer analyze for Ferrous and Non-Ferrous Materials

Monitoring QC, Laboratory Instruments & Melting Pyrometer calibration status and conduct the Calibration

Quality Assurance / Quality Control

Releasing material and process specification implementing stringent quality control system for incoming Raw materials and special process to enhance quality of products and reduce the rejection rate.

Monitoring Scrap (Rejection) Trend Machine Shop Vs Foundry on daily /weekly/monthly basis

Monitoring Monthly Foundry rejection level through 7QC Tool of Pareto Analysis

Update and Review all Quality Procedures and Quality Management System documents & Maintain Quality Records

Update and review the Process Quality Plan, SOP and qualify the special process periodically.

Monitoring Fettling process, Visual and Final Inspection for customer requirement

Conduct the Internal Audits & Training Programs for PPAP, 7QC TOOLS & 5 S Techniques

Conduct Process Capability study (SPC).

Update and Review the PPAP Documents (PSW, PIN, PFD, CP, FMEA)

Cost Reduction Analysis through Kaizen, Six Sigma & 5S Techniques

Responsible for Corrective & Preventive action

Experience in India: 14 years

May 2001 to Nov 2007 Working as a Quality Assurance Engineer / Laboratory In charge in M/S Praveen Foundry Private Ltd, Vellakinar, Coimbatore, India, The company manufactures Automobile components, Earth Moving components, Wind Mill components, Pump components, Valve components, Hydraulic components and Textile Components. (Ductile Iron 70%, Grey Iron 20% and Compacted Graphite Iron 10%) &It is ISO 9001-2008 Certified.

Technical and Executive Duties Responsibilities:

Responsible for all Incoming Raw Material Analysis

Responsible for Green sand process, CO2 Sand Process, Shell Sand Process and Coating Process control (Compression strength, Mould Hardness, Core scratch Hardness, LOI,VM, AFS, Specific Gravity, Viscosity, Baume and Hot Tensile Strength)

Metallographic, Hardness, Tensile, Impact Testing to as per standard & NDT Testing

Handling Customer complaints through 8D method for Corrective and Preventive Action

Handling with Third party inspection for Approval of sample Batch

Handling Spectrometer to analyze the Ferrous Materials

Field Failure Analysis of CPAP through 7 QC TOOLS

Monitoring and comparing Rejection level - Foundry Vs Machine shop

Cost Reduction Analysis through Kaizen, Six Sigma & 5S Techniques

Update and Review the PPAP Documents (PSW, PIN, PFD, CP, FMEA)

Evaluate Raw Materials supplier capabilities and sub-contractors capabilities

Monitoring the Production Performance, Delivery Performance and Rejection Level to communicate the Top Management.

Conduct the Internal Audit and update & review the QP, SOP

Key Tasks Handled Across the Tenures:

Handling project activities involving working out various requirements with respect to quality and reliability improvement, cost reduction

Developed Compacted Graphite Iron for wind mill component of VESTAS RB-GERMANY

Developed Compacted Graphite Iron (Vermicular) Hydraulic Component to EATON CORPORATION, USA

Developed Casting surface finish ( Green sand mould casting) through proper % of Lustrous carbon Material in low Level sand metal Ratio

Management Rewarded for above-mentioned achievement

Nov 2000 – Apr 2001 working as a Assistant In Charge Melting in M/S Ammarun Foundry Vilankuruchy, Coimbatore, India. The company manufactures Automobile components, Earth Moving Components, Pump components, Gear Components Valve components and Hydraulic components.

Aug 1998 – Nov 2000 Working as a Melting Engineer / Lab In charge in M/S Coimbatore Ductron Pvt Ltd., Avanashi Road, Coimbatore, India. The company is into manufacturing Automobile components, Earth Moving Components, Pump components, Heavy Electronic Components Thermal plant component, Sugar plant components, Valve Components and Hydraulic components.

Jan 1998 – Jul 1998 Working as a Melting Engineer in M/S Shanthi Gears Foundry Division Pappampatti, Coimbatore, India. The company is into manufacturing Gear Box components, Earth Moving Components & Pump components.

Apr 1997 – Dec 1997 Working as a Melting Engineer in M/S Seethalakshmi Steel, Coimbatore, India, Manufacturing Automobile components, Hydraulic Components, Textile components & Pump components .

May 1993 – Mar 1997 Working as a Lab Chemist / Melting Supervisor in M/S Ellen Ferrous Casting Arasur, Coimbatore, India. Manufacturing Pump components, Automobile Components & Gear Box Components.

Qualifications and Professional Training:

Bachelor’s Degree in Science – Chemistry, 1992

Madurai Kamaraj University, Madurai

Secured 69%

Internal Auditor (IRCA) - ISO 9001:2008 -Quality Management System, IQMS, by Business & Innovation Centre, and Sunderland - UK.

Lead Auditor (IRCA) - ISO 9001:2008 -Quality Management System, IQMS, by Business & Innovation Centre, Sunderland – UK.

Six Sigma Training - Concepts, Methodology, Tools and Techniques conducted for Green Belt Training organized by The Coimbatore Productivity Council, Coimbatore.

Trained In 7 QC Tools.

IT SKILLS :

Microsoft Office: Word, Excel, Power Point

Foundry Software

LANGUAGES KNOWN :

English, Tamil, HINDI & ARABIC

PERSONAL INFORMATION :

Date of Birth: Feb 7, 1971

Nationality: Indian

Marital Status: Married, 2 Children

Passport No.: Z3533811

Address: 61, Gandhi Nagar, Mettuthottam, Podanur Post, Coimbatore, Tamilnadu, India. PIN-641023



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