SHANKAR NAYAK K. M.

Apartment **, Building **, The Gardens, Jebel Ali, Dubai, UAE

+971*********, +971*********, acv5lu@r.postjobfree.com

Seeking Challenging Technical & Management Assignments with Learning Opportunities in a Growth Oriented Environment

Product & Process Metallurgy

Product Development / Evaluation

Process Control / Improvement

Research & Development

Materials Characterization

Aluminium Alloys Metallurgy

Metal Cleanliness Assessment

Defect Characterization

Failure Investigation

Quality Assessment

Technical Support

VDC Casting / Homogenizing

Strategic Planning

Training & Development

Performance Evaluation

Accomplished & goal oriented Manager, offering 20years of experience in research & development, product development, process control/improvement, application development, quality assessment, materials characterization, defect characterization, customer complaint investigation, SEM/EDX Analysis & optical metallography.

Expertise in VDC casting aluminium alloys, metal cleanliness, homogenizing, Open mould cast Al-Si foundry alloys, macro/microstructure evaluation, troubleshooting defects, root cause analysis, downstream rolling/extrusion processes, & semi-fabricated products.

Expertise in implementing, managing ISO 9001, ISO TS 16949 QMS & ISO 17025 accreditation of metallurgy services laboratory.

Aptitude to interpret business requirements into technology necessities supporting companies business objectives & capability to lead implementation, formulating efficient methods to monitor processes for successful delivery of project.

Possess deep knowledge of R&D and its implications within high risk work environments; excellent communication and interpersonal skills with a strong sense of arranging tasks & time management.

Successfully nominated for AVB Group Chairman’s award under “Distinguished Achiever” category in 2005.

Participated & contributed in discussions in “Novelis Sheet Product & Process Metallurgy course at Gottingen, Germany.

Played significant role in the development of Al 5XXX series plates for light weight railway freight wagon with enhanced payload-to-tare weight ratio & acquiring vendor approval from Indian Railways.

Successfully developed Exfoliation & Intergranular corrosion resistant temper Al-Mg alloy for transportation & marine applications.

Proven casting & homogenizing practices for 6XXX series Wagstaff Airslip VDC cast billets exceeding customer specifications & zero customer complaints.

Guided Process & Metallurgy team in troubleshooting casting defects & reduction of butt discard improving recovery.

ISO 17025 accreditation of Metallurgy Services Laboratory at Emirates Global Aluminium, Abu Dhabi.

Successfully investigated more than 200 surface defects in Aluminium rolled & extruded products using SEM/EDX analysis & Optical metallographic techniques identifying root cause enabling corrective actions.

Presented technical paper on “Characterization of Defects in Aluminium Rolled Products” at Indian Institute of Metals & Non-ferrous Metals Conferences.

Successfully developed Insitu Metallography technique for Remnant Life Assessment at Thermal power plants.

Emirates Global Aluminium (EGA-EMAL), Abu Dhabi, UAE, Nov 2010 – Present

Responsible for Metallurgy & Process Control of Wagstaff Air Slip VDC Billet Cast & Homogenized 6XXX series Aluminium Extrusion Billets & Open Mould Cast Al-Si Foundry Ingots

Superintendent - Metallurgy

Managing & furnishing functional support in administering a team of metallurgy engineers & technicians in extrusion billet casting, homogenizing & open mould cast Al-Si foundry ingots. Controlling the team to transmit out process monitoring & product evaluation in accordance with the customer specifications as well as in performing the metal cleanliness (Alscan Hydrogen, PoDFA) and optical metallographic activities in extrusion billet casting & homogenizing as well as foundry alloy ingots. Continuous improvement of processes including TAC, furnace preparation, inline grain refining, ACD/Hycast I-60 SIR degassing, CFF Filtration, Wagstaff Air Slip

VDC Billet Casting, & Hertwich Continuous/Batch Homogenizing. Recommending metallurgical equipment to deliver the mandatory services for technical development in casting & homogenizing process to encounter the technological as well as market necessities. Implemented systematic assessment of alloying elements to contribute in continuous improvement of product quality & recoveries.

Developing & executing metallurgical procedures to offer complete metallurgical services for metal quality assessments, process control, customer complaints & technical support to contribute quality & process improvements and customer’s happiness.

Collaborate with the activities for optimum use of metallographic laboratory/workshops to confirm that equipment are available in optimum working condition for evaluating all cast house products.

Strategically represent as an area manager in the investigation of customer complaints & technical support to sustain customer satisfaction level & contribute in joint development work with customers.

Recommend product benchmarking against the competitors to continue competitive edge, coordinate the training & development of all metallurgical engineers & technicians to enhance technical competence.

SAPA HEAT TRANSFER (ORKLA INDIA LIMITED), Mumbai, India, May – Oct 2010

Responsible for Product Development & Technical Support in Al Heat Exchanger Materials for Automotive & HVAC Customers in India

Head – Product Development

Headed & organized all the functions related to product development which included facilitated customer’s objective to improve products, economical solutions and supported customers goals and targets. Performed activities including meeting customers & technical training for application of Al HEX material in accurate condition, regularly. Worked closely with customers to know about particular necessities, resolved complications on-site with regular appointments. Assessed customer specification, established product specification in agreement with customers and restructured material database on competitor material analysis & benchmarking on regular basis.

Controlled material quality complaints & claims, troubleshooting, made actions first time to satisfy customers, facilitated with customer to explain the problem & followed up CAR.

Promoted new HEX materials to customers to increase the competitive capability of the company in market on continuous basis & developed new market by functioning as advanced sales for potential customers.

Achieved annual target for Indian market according to SAPA KPI’s, implemented the task & appraised the performance results regularly with Product Development Head at SAPA, Shanghai.

HINDALCO INNOVATION CENTRE TALOJA (HICT), HINDALCO INDUCTRIES LIMITED, Taloja, Navi Mumbai, India, 2004-2010

Responsible for R&D Project Management, Product/Process Development, Managing Metallurgical Laboratory, Technical/Analytical Services across Hindalco Casting & Semi-fabrication Plants

Sr. Manager – Technology

Managed a metallurgy team & executed R&D projects in line with Aluminium Semi-fabricated business objectives. Identified key results areas in consultation with technology function & aluminium semi-fabrication plants. Implemented capital expenditure projects for R&D and evaluated new techno-economical process technologies for application Al downstream. Developed & sustained metallography laboratory, ensured calibration of metallurgical equipment & investigated customer complaints resolving customer product issues. Provided technical support in Aluminium semi-fabricated product/process metallurgy to Hindalco plants, guidance in Aluminium metallurgy to plant product/process metallurgists, confirmed adherence to ISO 9001:2000 QMS requirements, directed internal quality audits & followed non-conformances to closure.

Headed & contributed in the research & development, product development, process improvement projects alongside detailed action plans, techno-economical feasibility studies, coordinated resources for execution & controlled progress of individual objectives.

Interpreted results, approved gaps for improvement, arranged detailed technical reports with recommendations and collaborated with validation of laboratory findings by plant trials.

Developed optical metallographic laboratory, specified laboratory equipment, acknowledges suppliers, technical discussions & negotiations, and brush up specifications in an efficient manner.

Established technical information centre with technical books, FM’s, technical reports, journals on Aluminium metallurgy, updated international/national standards, capturing to plant metallurgists by conversation of collections, intelligences & e-mails.

TALOJA R&D CENTRE, INDIAN ALUMINIUM COMPANY LIMITED, Taloja, Navi Mumbai, India, 2000-2004

Responsible for Metallurgical Services & Technical/Analytical Support for Product Development, Process/Quality Improvement

Manager – Technology / Deputy Manager - Technology

Managed a team of metallurgy engineers & directed all the functions related to Scanning Electron Microscopy, Energy Dispersive X-Ray Analysis, optical metallographic activities & mechanical testing to support Aluminium product & process development. Successfully developed methodology for characterization of surface defects Aluminium alloy rolled products – Sheet & Foil & extruded profiles from Hindalco’s semi-fabrication plants using techniques like visual & macro examination, optical metallography, SEM/EDX Analysis, literature survey, process history followed by root cause analysis to identify origin of the defect. Approved SEM/EDX fingerprinting of sheet, foil & extruded profile processing contact materials at Hindalco plants as a prerequisite for defect investigation. Regulated metallurgical & mechanical testing laboratory equipment. Collaborated with external laboratories for outsourcing testing facilities & implemented 5S housekeeping in metallography laboratory & work place.

Considered more than 200 surface defects in Aluminium alloy rolled & extruded products for pinpointing root cause & appropriated corrective arrangements at Hindalco’s rolling & extrusion plants.

Proficiently delivered technical services to Hindalco’s semi-fabrication plants for evaluating grain refiners & master alloys from various sources such as LSM, KBM, & Aleastur as well as microstructure analysis of products for various applications.

Successfully optimized macro/microstructure of VDC cast aluminium alloys rolling ingots for lithographic & foil packaging applications.

Supported over 100 literature survey’s and compilations in metallurgy facilitating trouble shooting, product, process, application development and quality improvement in aluminium semi-fabricated products.

Executed ISO 9001:2000 standard requirements, developed quality plans, general & technical procedures & work instructions for metallurgical services to Hindalco semi-fabrication plants.

JEWEL METALLOCHEM LABORATORY, Mumbai, 1996-2000

Optical Metallography, Mechanical/Corrosion Testing, Failure Investigation, Insitu Metallography under 3rd Party Inspection

Metallurgist

VISHAL DESIGN PRIVTAE LIMITED, Mumbai, 1995-1996

Project on Gold Jewellery Production Using Investment Casting & Electroforming

Metallurgical Engineer

Optical Microscope (Reichert Jung, Carl Zeiss), Image Analyzer (SIS Olympus, Carl Zeiss), Metallographic Specimen Preparation Equipment (Struers, Buehler), Scanning Electron Microscope & Energy Dispersive X-Ray Analyzer (FEI/Philips, Oxford),

Alscan Hydrogen Analyzer (ABB), PoDFA Inclusion Sampling & Metallographic Analysis of Inclusions (ABB)

Tensile Testing (Instron), Hardness Testing, Impact Testing (Charpy), Earing & Cupping Test (Erichsen),

Surface Roughness (Mitutoyo), Surface Gloss (Sheen Instruments), Electrical Conductivity Meter (Fischer),

Pin-on-Disc Abrasion Wear Testing (Ducom), Differential Scanning Calorimetric (DSC) Analyzer (TA Instruments),

Intergranular Corrosion Testing of Stainless Steels, NAMLT & ASSET Corrosion Testing of Al-Mg Alloys,

Optical Emission Spectrometer (ARL), Electro graining & anodizing of Aluminium Alloys,

Member of Technical Committee of Aluminium Association of India (Past),

Member of Bureau of Indian Standards Committees – Mechanical Testing of Metals Sectional Committee MTD 3, Light Metals & Alloys Sectional Committee MTD 7, & Metal Containers Sectional Committee MTD 32 (Past)

M. Tech., (Process Metallurgy) ; Regional Engineering College, Suratkal (NITK), Karnataka, India in 1995 - 78% with Distinction (GATE Scholarship during M. Tech., course for 18months),

Industrial Training at SAIL Steel Plant, Bhilai, M. P., India from July 1994 to August 1994 as a Part of M.Tech. Course

M. Sc., (Materials Science); Mangalore University, Karnataka, India in 1993 – 70.5% with Distinction

5 days Training Program on “Wagstaff Air Slip VDC Billet Casting of 6XXX Alloys” by M/s Wagstaff Inc., USA Representatives

One month Plant Process & Product Orientation Program at M/s Sapa Heat Transfer Shanghai Limited, Jiading, Shanghai, China

5 days Aluminium Sheet Process & Product Metallurgy Training organized by M/s Novelis, Germany at Gottingen, Germany (Novelis became part of Hindalco in 2007)

5 Days Training on Heat Exchanger Brazing Stock Manufacturing Technology by M/s Innoval Technology, UK

5 Days Training on Aluminium Industrial Electrolysis by M/s The Minerals, Metals & Materials Society (TMS), USA at Dubai, UAE

5 day course on Welding of Aluminium Alloys conducted by Welding Research Institute (WRI), Bharat Heavy Electrical Limited (BHEL), Trichy, Tamilnadu, India

Successfully Qualified ISO 9001: 2000 QMS Lead Auditor Course Organized by BVIS, Mumbai (2005)

Failure Analysis training program organized by ASM International Pune, India Chapter, & Sheet Metal Forming Course organized by IIT-Bombay, India

General Management Programme, Talent Management Programme & Training on Analytical Thinking & Problem Solving organized by Hindalco Corporate HR

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