Engineer Quality Control
Resume:
Curriculum Vitae
Abdul Azees Shaik
Metallurgist - Steel Plant and Rolling Mill Long Products
Section Head - Technical Services Department
Emirates Steel Industries,
ICAD – Musaffah, ABU DHABI.
United Arab Emirates,
PB No – 9022.
Mobile No - +971-**-*******
Office No - +***-**-****-947
Residence No - +***-**-****-944
E-mail – **.*****@*****.***
**********.*****@*************.***
Bright Experienced Metallurgical Engineer with Experience in All Facets of Production ( Steel
SUMMARY
Making through EAF-LF-CCM route, Rolling Long Products – High Carbon, Low Carbon,
Alloy and Structural Deformed products), Quality Control, New Product Development,
Failure Analysis, Productivity Improvement, Cost Reduction, Customer Relation, Customer
Complaints, and Billet /Coil/Bar Alloys and API Line Pipe Steels.
M.Tech (MS) in Metallurgical Engineering from Institute of Technology, Banaras Hindu
EDUCATION
University (IT-BHU), India in 2004 – 2 years
AMIIM (BS) in Metallurgical Engineering from Indian Institute of Metals, India in 2001 – 2
years
D.Met.E (Diploma) in Metallurgical Engineering from Govt. Polytechnic in India in 1999 – 4
years.
EXPERIENCE
2014 – Present EMIRATES STEEL INDUSTRIES, Abu Dhabi, UAE as a Metallurgical Engineer –
Integrated steel mill with 3.0 million tons annual production capacity.
Acting as Section Head – Quality Control Department for Melt Shop, Rolling Mill and DR
units.
o Providing support in the coordination and evaluation of external customer requirements in
accordance with the capacities and capabilities of the production departments (i.e. Steel
Making and Rolling), and ancillary service departments (i.e. process and product
metallurgy, material handling marketing).
o Responsible for the identification, implementation and co-ordination with the Melt Shop,
Rolling Mills and other departments of process / product development projects designed
to improve product quality and yields as well as reduce processing costs.
o Providing technical support and training to a broad range of people including leadership,
internal engineering, manufacturing, project management, sales, and field operations; as
well as customers, suppliers, and third party agencies
o Develops, implements, and ensures utilization of metallurgical methods, procedures and
specifications for raw materials, processing materials, finished products and equipment
operation in manufacturing operations.
o Develops and executes metallurgical projects to control scrap, improve the manufacturi ng
process, improve product quality, and reduce costs.
o Aid in development of processes and practices necessary to produce grades of steel to
comply with industry, customer, sales and operating requirements.
o Conducting metallurgical investigations relating to process control and product
development
o Providing material recommendations for research and new product development and to
meet customer and/or industry requirements
o Developing and maintaining internal specifications for raw materials, Semi finished
products and finished products and others to assure compliance with applicable industry
standards and best practices
o Writing accurate and persuasive technical reports detailing causes and corrective actions
associated with analysis of data and issues
o Aid in development and implementation of timely, effective quality reporting systems
o Support process/product engineering activities in terms of cost reduction, quality control
and troubleshooting.
o Using statistical techniques and software to evaluate changes to product specifications
and to interpret historical production data as well as results of laboratory studies
o Develop and document procedures for non -conforming and/or obsolete products to ensure
product quality is not affected.
Worked in HARSCO CORPORATION (NYSE:HSC) as Metallurgical Engineer based in
2012-2014
Dubai, UAE.
Acted as Regional Technical Manager - Metallurgist for Middle East, North Africa and India.
Harsco provides high value industrial services and Metallurgical Solutions to major global
steel maker.
o Provide technical consultation and guidance to Harsco production management, quality
control and technical sales staff for new product launch programs. This includes
providing insight on material usage and performance, resolving performance problems,
incorporating formulation changes, investigating raw material procurement and other
pertinent activities as may be required.
o Discuss with customer technical personnel and Harsco technical and operations staff for
the exchange of highly technical product design, formulation and performance
information.
o Regularly visit customers their locations, analyze current process practices and develop
appropriate recommendations for product/practice revisions Provide technical support to
the Harsco Metals Business Development and Commercial teams as well as site
operations managers.
o Consult and provide solution to steel makers for Continual Improvements, cost reduction,
Productivity improvements etc.
o Liaise with the global technical experts on product performance and product development
o Assist in the resolution of product design/performance and process problems.
o Engage in dialogue with customer technical and production personnel regarding new
product concepts designed to solve customer problems and generate Harsco sales.
o Present proposals and run trials of new product formulations at customer locations.
o Prepare and maintain all documentation necessary to support product evaluation and sales
development.
o Record and analyze data from trials of new products and practices. Use this information
to refine product proposals for Harsco and customer staff.
o Provide input as required by Harsco sales management for producing sales forecasts.
o Provide formulations and the supporting documentation necessary for quoting products
within the margin and competitive pricing constraints
Worked in PT ISPAT INDO, Indonesia as Metallurgical Engineer - Steel Mill with 0.60
2010-2012
million tons annual production capacity. PT Ispat Indo is a sister company for Arcellor Mittal
Inc.
Acted as Department Manager for Quality and P roduct Development Department for Melt
Shop and Rolling Mills.
o Monitoring the process parameters of Electric Arc Furnace, Ladle Refining Furnace and
Continuous Casters for different International Steel Grades and ensuring the heat cast
without any deviations.
o Implementing process control activities to arrest the casting defect, deviations in heats
online.
o Route cause analysis of various casting defects like surface cracks, transverse cracks, slag
entrapments etc and finding solution to avoid re-occurrence.
o Planning of In-put Materials required for EAF & LRF and ensuring for smooth
production of Shop. Freezing the optimum charge mix to get desired chemistry according
to grade of steel.
o Analysis on various delays occurred during EAF & LRF processing and find out the
solution to avoid re-occurrence.
o Regular testing of semi-finished products (billets/blooms) and finished products (wire
rods) for heats on sample and providing clearances and certifications.
o Calculating the techno-economics of steel making route with best possible way to reduce
the cost of steel making.
o Educate the work force of the departmental technically & economically to minimize
various wastages for cost reduction of steel.
o Cost reduction technique implementation in wire rod mill, l ike Hot Charging, Changing
cooling pattern to get higher mechanical properties at same chemistry level etc.
o Interacting with Marketing, PPC & Customers for reviewing Technical Delivery
Conditions (TDC) and developing the customer specifications as per inte rnational
standards e.g. SAE, AISI, ASTM, API etc.,
o Implementing new and advanced technology to reduce cost and increase productivity at
shop floor.
o Ensuring Smooth functioning Wire rod mill, In case any D efects in wire rods, Fee back to
WRM.
o Ensuring the right material delivery to customer according to mechanical and chemical
properties as per International standards.
o Analysis of Delays due to coble, break downs and feed back to Rolling Mill Operations.
o Micro Analysis of different size of wire rods and correlation with mechanical properties.
o Process Control activities, like monitoring of THF temp, rolling speed, conveyor belt
speed and standardize with Micro & Mechanical Properties.
o Attending customer complaints, route cause analysis of complaints and implementing
corrective and preventive actions.
o Optimization of mechanical properties with respect to Chemistry, Rolling Temp &
cooling pattern.
Worked in JINDAL STEEL AND POWER LIMITED, India as Metallurgical Engineer –
2006-2010
Jindal Steel is an integrated steel plan with 3.6 million ton annual production capacity.
Acted as Deputy Manager in Quality Control Department for Semi finished billet/bloom/beam
blanks and slab units.
o Process Control of EAF, LRF and Continuous Caster (6 Strand Billet, 4 Strand Bloom &
Slag caster) and Degassing Units - VD Tank & RH Degasser and standardization of
Process Parameters for various products.
Modeling – Participated in Water Modeling of 35 MT Tundish for Slab Caster to reduce
o
skull generation.
o Designing the chemistry according to final mechanical properties for developing new
products.
o Failure analysis and responsible for implementation of Corrective and Preventive action
for continual improvement.
o Testing the mechanical (UTS, YS, Elong, Impact etc) and internal soundness (Macro,
Micro and Sulphur print etc) of the steel grades
o Conducting Industrial Projects and implementation to reduce the cost of Steel making,
Improve the Productivity, Improve the Quality and product development.
o Product Development. Contributed to develop Ultra Low Sulphur steel, Bearing Quality
Steels, API Grades.
o Testing of heats on sample basis to ensure sound produce is delivered to customer as per
technical delivery conditions.
o Receiving customer inquiries, discuss and finalize the customer specifications accordi ng
to international standards.
o Attempting customer complaints, understanding the issues and resolving/settling the
complaints.
o Testing of all input material for steelmaking such as hot metal, DRI, Lime, Dolo, Coke,
ferro alloys etc and ensuring the suitability according to melt shop requirements.
o Daily man power management, providing on job training and safety training to
departmental employees to make sure accidental free operations.
o Attending regular operation meetings, providing daily quality reports, update with
rejection analysis and reason for the deviations to make sure quality of product.
o Interacting with production planning team for proper planning based on available stocks
and ensure not to produce surplus quantities.
Worked in USHA MARTIN LIMITED, India as Metallurgical Engineer – Usha Martin is an
2004-2006
Integrated Steel Plant with 1.1 million tons annual production capacity.
Acted as an Engineer in Technical Cell and Customer Handling Department for Steel Melt
Shop and Rolling Mill Units.
o Handling of Customer Complaints.
o Failure analysis by Microscopic, Macroscopic Examination.
o Receiving customer inquiries discuss and finalize the customer specifications according
to international standards.
o Product and process designing as per customer specification considering various National
and International standards.
o Failure analysis and implementation of corrective and preventive actions on the process
chain.
o Review of Effectiveness of corrective and preventive actions in every quarte r and
subsequently planning of further action plan through PDCA cycle.
o Micro Analysis of different size of complaint samples for route analysis of the problem
o Using statistical techniques and software to evaluate changes to product specifications
and to interpret historical production data as well as results of laboratory studies .
AREAS OF Steel Product Categories
EXPERTISE o Construction grade structural low carbon steel
o API Quality steel grades
o Carbon Steel – Low, Medium & High Carbon Long products
o Re-sulphurized Steels
o Rail Steels
o Micro Alloys steels
Steel Making by Electric Arc Furnace route
o Operated 40 tones, 40 MVA EAF as Furnace In -charge for short period of time at
Usha Martin Limited.
o Optimized process parameters of 100 tone, 100 MVA EAF at Jindal Steel &
Power Limited, Raigarh
Secondary Steel Making by Ladle Refining
Continuous Casting of Billets, Blooms and Slab
o Worked to control various casting defect at JSPL in Slab Caster with the cast size of
215 – 280 mm thickness & 1500 – 2620 mm width
o 6 strand Billet caster having section sizes of 140, 160, 200, 220 Dia round and
130X130, 160X160, 200X200 mm blooms
o 4 strand Combi caster having section sizes of 305 Dia round and 250X250, 285X390
mm blooms
Rolling Mill – Long Products
o Detection of deviations during online rolling and Eliminating before production.
o Worked to control cobles, optimize mechanical and micro structural properties by
optimizing the THF temperature.
o Customer Enquiries for New Grade development, resolving the Complaints, freezing
of raw material quality for supply.
o
CAREER Developed API grades like API X52, X60, X65 and X70 in Slab sections
ACHIEVEMENTS conforming to the standard of American Petroleum Industries.
o Development of Boron bearing seamless steel grade in round cast sections for API
line pipe application
o Contributed to increase Yield in Steel making area from 86% to 89% which has given
huge savings.
o Contributed to increase the productivity by changing the casting sections from
150X150 to 160X160 mm mold in Steel Casting.
o Reduced the prime metal losses in rolling mill by optimizing the shear end cuts
during rolling which given benefits of 360 MT per Year prime steel saving.
o Development of Re-sulphurised Medium Carbon Alloy steel grades for Automobile
application.
o Contributed for the development of High Si steel 32HiSi and subsequently rolled and
supplied to customer.
o Elimination of Longitudinal surface cracks in slabs & Beam Blank sections.
o Standardization of process parameters of RH degasser for Rail steel manufacturing to
achieve hydrogen level 1.60 ppm max.
Team member of project “ Reduction in Yield loss in Slab caster tundish “ in
o
collaboration with IIT, Kanpur.
o Reduced coble from 28 Nos to 4 Nos per month by optimizing the shear cutting,
billet quality in Ispat Indo.
o Reduced the flux consumption in SMS from 70 Kg/MT to 55 Kg/MT by foamy slag
optimization, sequential addition of flux etc.
o Contributed to reduce rejection of Nails from 78% to 5% by implementing stan dards.
o Published 7 papers in International and National Journals
o Delivered oral presentations in NMD -ATM & IIM Delhi for 2 times
o
INDUSTRIAL Recycling of Iron ore fines by Briquetting Technique
PROJECTS o Control of Nitrogen during processing of steel in EAF
CONDUCTED o Improving the yield from the 36 T slab casting T undish by slightly modification of
Tundish Design.
o Analysis on the longitudinal cracks generation in Beam Blanks.
o Reduction of Steel Manufacturing Cost at EAF.
o Analysis on using of Launder Practice to pour Hot Metal in EAF
o Analysis of Longitudinal Crack formation in Slabs
TPM (Total Productive Maintenance) : Conducting ‘Why-Why’ Analysis and ‘4W-
o
SYSTEMS
ADEQUACY 1H’ Analysis to find out the root causes incase of failure oc curred.
o ISO 9001 System : Preparation of PPAP, Control Plans, FMEA and APQP. Certified
Internal auditor of ISO 9001:2000 & ISO 14001:2000 (Training conducted by BSI
Consultancy )
o Undergone training on TS 16949:2001
o
PAPERS DRI Apparent Density and its Strength, ISIJ International, Vol 45, No. 3, 2005, p
PUBLISHED 408.
o Briquetting: A New approach to recycle the waste Iron-bearing materials generated in
Steel plants, J.Metallurgy and Material Sciences, Vol 4, p 292 – 296, 2005.
o Modified practice for the production of steels with low nitrogen level in Electric Arc
Furnace, Transactions of IIM, 2007, (Under Review)
Poster Presentation on “Development of Ultra Low Sulphur Steel for Critical Sour
o
Gas Line pipe application at JSPL” at NMD ATM – 2007, IIM, Mumbai.
Development Of “Resulphurised Clean” Medium Carbon Alloy Steel For “Critical
o
Auto Component, 2008, Steeltech, Vol 2, No 3, April, p 38 -41.
o Development, Of Nb-bearing Microalloy Steels; JSPL Experience, Oral & Paper
presentation in Delhi, IIM Delhi & Ministry of Steel, 2009
o Relevance of Direct Reduced Iron in EAF Steel Making; JPC Bulletin, May 2009,
Vol IX, Issue 05, p 18-27
COMPUTER Having good knowledge of languages like C, C++, FORTRAN 77, Operating system e.g.
PROFICIENCY Windows, Windows NT, Windows XP, WordStar, Lotus 123 and Packages e.g. MS-Office,
Origin, Curve Fitting.
o Contributed for Implementation of SAP 6.0 ECC at JSPL
o Implemented SAP modules of PP & QM in PT Ispat Indo
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