Ouality control

S.Santhosh Kumar

#**/*, *** ***** ******** Street, Mavalli,

Bangalore.

Email: acp9aj@r.postjobfree.com / acp9aj@r.postjobfree.com

Mob: 097********

WELDING & QUALITY ASSURANCE ENGINEER

Seeking challenging assignments for a career encompassing professional & personal advancement across the Industry

PROFILE

A highly motivated and dynamic Welding and Quality Assurance Engineer with remarkable success directing towards statistical quality control and Six Sigma

An enthusiastic person holding good track record with hands on experience on Structural Assembly and Non Destructive Testing (NDT) methods.

• Competent and dynamic Welding and Quality Engineer in Aerospace and Mechanical field, with 7+ years experience in Welding Inspections, handling QA/QC Inspection, NDT, Piping and Welding Inspections.

• Successfully Leaded the NADCAP AUDIT for WELDING in achieving the NADCAP CERTICATION for RSTPL.

• APPRECIATED by the management for the preparation of PROCEDURES AND DOCUMENTS presented in the NADCAP AUDIT.

• Well acquainted with total quality control aspects in various surface preparation methods, various application methods, various paint & coating systems, including high performance hi-tech products, various practical problems, etc.

• Hands on Experienced Preparation of Production & Quality related documents (PFD, Control Plan, FMEA and Production Time Plan).

• Hands on Experienced in conducting stage wide welding quality checks, carrying out Welder Qualification Tests, Procedure Qualification Records, Preparing Welding Diagram and Welding Procedure Specifications.

• Core competencies in Inspection of Incoming Materials, Evaluating the Radiography Films, NDT Clearance of Loop Packages, Evaluating of UT, MPT, DPT, Inspection of Painting Jobs and Reviewing the Post Weld Heat Treatment (PWHT) charts.

• Hands on experience in managing inspection activities, preparation of Welding Procedures Specification (WPS), and Procedure Qualification Record (PQR) and witness of welder qualification test.

• Thorough understanding of Health & Environmental Safety Methods as per set standards and professionally competent in implementing safety norms across diverse industrial systems / processes.

Core Competencies:

• Statistically quality control and six sigma

• Non destructive testing methods

• Body panelling

• Welding Procedure Specification, Procedure Qualification Records Qualifications,Welding inspection & defect analysis

• ASME, NAS410 & NADCAP codes and standards

• ANSYS,NASTRAN,HYPERMESH and AutoCAD

• Windows XP and Microsoft Word, Power Point and Excel

• Knowledge on usage of measuring instruments and gauges.

• Follow-up of calibration of measuring instruments and gauges.

• Analysis and control of internal Non-conformity.

• Resolving issues pertaining to quality,

• Providing training to subordinates

• In coming inspection, In-process / line inspection and final inspection.

• Monitoring the Calibration status

Career Experience:

1. SENIOR Engineer (Welding &Quality) – RANGSONS SCHUSTER TECHNOLOGIES PVT LTD, Creating Aircraft Aviation Tubes and Hoses, Mysore, September2013- present.

“Rangsons Schuster Technologies pvt ltd”, is a joint venture company of Indo-Israel. Manufacturing of Aero Pipe Assembly’s and Aero Hose used in Aero Engines. An AS9100 -2009 and NADCAP for Welding certified Company.

Nature of work: Currently involved in the Inspection of weld joints in pipes & Hoses (Aviation Rigid Tubes, Flexible Hoses, air, fuel & oil lines, Aero-engine component) used for Jet Engines, Space &Missiles.

• Preparing and qualification of Procedure Qualification Record and Welding Procedure Specification and conducting the welder qualification test and monitoring all parameters as per WPS.

• Checking of consumables used in welding to ensure compliance with specification and monitoring welder’s performance and to ensure that they are performing within the limits of their qualifications.

• Ensuring safe and proper welding practices are employed at all times. Performing verification and validation of the calibration certification of welding machines / inspection equipments as per requirements.

• Prepared all Welding related procedures and documents for NADCAP AUDIT for Welding.

• Preparation of Production & Quality related documents (PFD, Control Plan, FMEA and Production Time Plan).

• Training persons on FOD Control & 6S.

• Currently handling Honeywell project (Production & Quality Process related Documentations) and leading the production team to achieve the Daily, Weekly and Monthly targets to satisfy customers on time schedule delivery.

Achievements:

• Successfully Leaded the NADCAP AUDIT for WELDING in achieving the NADCAP CERTICATION for RSTPL.

• APPRECIATED by the management for the preparation of PROCEDURES AND DOCUMENTS presented in the NADCAP AUDIT.

• Standardized the process for Product Quality control.

• Increased the production rate to 75%.

• Controlled of scrap rate from 40% to 16%.

2. SENIOR Inspection Engineer (QA/QC &NDT) –NATIONAL INSTITUTE OF ROCK MECHANICS, BANGALORE, May2012 - August2013.

• Ensuring all inspections and tests are carried out as indicated on the appropriate Inspection & Test Plan.

• Reviewing corrective actions recommended in non-conformance reports, initiate and verify corrective actions to prevent reoccurrence of non-conformity.

• Preparing and qualification of Procedure Qualification Record and Welding Procedure Specification and conducting the welder qualification test and monitoring all parameters as per WPS.

• Checking of consumables used in welding to ensure compliance with specification and monitoring welder’s performance and to ensure that they are performing within the limits of their qualifications.

• Ensuring safe and proper welding practices are employed at all times. Performing verification and validation of the calibration certification of welding machines / inspection equipments as per requirements.

• Monitoring Preheating, Post Weld Heat Treatment, and NDT and controlling weld repair by analyzing the root cause and implementing corrective action to prevent recurrence.

• Preparing Daily, Weekly and Monthly inspection / testing reports and managing all the documents related to the contract. Preparing Hydro Test Packages and monitoring the completion of punch list.

Projects as 3RD Party for:

• Hindustan Petroleum Corporation Limited, Visakhapatnam Refinery, for American Bureau of Inspection Service.

3. NDT Engineer- SNECMA HAL AEROSPACE PVT LTD, Bangalore

Oct 2008 –May 2012

“Snecma-HAL Aerospace Private Ltd”, is a joint venture company of Snecma (Group Safran) and HAL. Manufacturing of Aero Pipe Assembly’s used in Aero Engines. An AS9100 certified Company and One of the Leading 100 % EOU industry in Bangalore.

Nature of work: Involved in the Inspection of weld joints in pipes (air, fuel & oil lines, Aero-engine component) used for CFM-56 Engine manufactured by M/s. SNECMA in France.

Radiographic (x-ray) Testing & Inspection: Duties & Responsibilities:

• Taking X-ray of all the detailed parts for the projects and interpretation of the films for the welding defects.

• Maintaining Inspection records along with x-ray films for traceability.

• Maintaining the details of parameters like type of film, kV, mA, focal length, film density, focal length, developer and fixer concentration which is in use,

• Procurement of x-ray film, developer, fixer, consumables and safety items before the stock is exhausted.

• To carryout periodic verification of installation pertaining to x-ray machine and products as per the required standard.

• Study of drawings, process sheets, standards, specific technological requirements and implementation.

• To ensure the sequence of operations given in the process sheets/route card are followed.

• Follow up of periodic Calibration of image quality indicator (IQI), Negatoscope, densitometer and maintaining proper records for them.

• To give training to new comers for operating the x-ray machine whenever required.

• For implementation of any new x-ray parameters / method based on customer requirement.

• Maintain cleanliness of all the inspection areas.

• To complete other works assigned to me from time to time.

Penetrant Testing (Fluorescent dye): Duties & Responsibilities:

• Inspection of all the detailed parts for the projects by fluorescent penetrant inspection method.

• Ensuring the parameters like type of penetrant and developer to be used, and procurement of penetrant & developer

• Study of drawings, process sheets, specific technological requirements and implementation.

• To ensure the sequence of operations given in the process sheets/route card are followed

• To ensure that all the pressure gauges, temperature controllers, timers, U.V lamp, test panel / instruments in use have valid calibration and arrange for periodic calibration of such instrument.

• To maintain all calibration records pertaining to FPI.

• To give training to new comers for operating of FPI booth whenever required.

Achievements:

• Product Quality control.

• Successfully reduced defect rate from 45% to 5% by performing Design of Experiment (DOE).

• Reduced scraps by 1.8% every month to facilitate higher production rate.

• Increased the production rate by 30% during the quarter results.

4. NDT Engineer - Southern Inspection Services, Chennai Jan 2007 – Sep 2008

• Managing 3rd party inspection projects for oil and shipping clients.

• Performing NDT testing to identify the load carry capacity and validating product durability.

• Advising client’s on thickness coating for various parts and products.

• Preparing detailed reports for 3rd party clients.

Achievements:

• Encouraged and enhanced testing processes from A-Scanning to B-Scanning to better utilize time and labour.

• Increased repeat business ratio by 25%.

• Achieved and improved product efficiency from 50 to 60%.

5. Production Supervisor Jaico Automobiles Volvo Division (B’lore)

Jul 2006 – Dec 2006

• Regularly inspecting structural processes and procedures for designing various parts.

• Supervising shifts, preparing shift rota for staff’s and provided appropriate training.

• Stocking and reporting on all sub assembly parts and products.

Achievements:

• Effectively trained and inducted staff thus decreased man hours by 10%.

• Improved production thus reduced the scrap rejection rate by 2%.

Industrial Trainee HAL & BEML (B’lore & KGF) Mar 2006 – Jul 2006

• Trained on NDT testing (Radiography Testing) for engine shafts, cellular shafts, tangent shafts and elliptical shafts.

• Developed knowledge on various machining processes and flaw detection by stress methods.

• Enhanced welding skills and improved problem analysing skills on wielding defects.

Technical Projects:

• Analysis and welding defect controls on fuel pipelines.

• Design of experiments in controlling oxidation and cavity in GTAW welding.

• Finite element analysis and fatigue life prediction of welded joints.

Education:

Bachelors in Mechanical Engineering, Golden Valley Institute of Technology, India 2002 – 2006

Trainings & Certifications

• Certified in Statistical Quality Control, Indian Statistical Institute, 2012

• Green Belt Six Sigma, Indian Statistical Institute, 2012

• Non destructive Testing Level II (UT, RT, MT, PT, Infrared thermograph and Eddy Current) American Society, 2007

• Participation in NADCAP Certification, National Aerospace and Defence Contractors Accreditation Program, 2011

• EN 4179 and NAS 410 Level II Certified in Radiographic and Penetrant Testing Inspection, National Aerospace Standard,2011

• Hyper Mesh, Nastran, ANSYS,AUTOCADD AND MS Office.

Declaration:

I hereby solemnly declare that all the information duly furnished is absolutely true to the best of my knowledge, understanding and ability.

(SANTHOSH KUMAR. S)

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