Manager Quality

DAMODAR GURUGUBELLI

Mobile: +1-832-***-****, Location: Baytown - Texas, E-Mail: *********@*****.***

~ Senior level professional ~ Quality Assurance ~ Quality Control ~ NDT Industry preference: Steel plants, Technical & Digital industry, Established Oil & Gas companies Executive Snapshot

Qualified Engineer with over one and half decade of experience (About 18 Years) in Technical, Quality Assurance, Quality Control, NDT & DT, Metrology and Metallurgy in India, UAE and USA.

Currently associated with (Drill Pipe International / Jindal) Baytown, TX as a Quality Manager with merit of setting up quality inspection, testing, measurement and process as per industry standards.

Possess thorough knowledge and vast experience in the areas of:

Specifications: API 5DP, 5CT, 7-1, 7-2, 5L, DS1, NS1, NS2, NS14, 5B and Q1.

Recommended practice: API RP 7G, IRP.

Standards: ASTM, ASME section IX, ASM, BS and ISO.

Non destructive testing: ASNT Level III certified in MT & UT (# 187281). Level II in RT, PT, and VT.

QMS: Lead auditor certification on ISO 9001:2008.

Tools: SAP, MS-Office, Inventory – JIMS, TRACS…etc.

Significant experience in successfully designing and establishing processes, procedures, coordinating inspections

(in-process and processed) and testing.

Experience in successfully monitoring and maintaining for ISO and API quality management systems.

Keen understanding of TQM, 5S approaches and failure analysis, with success in implementing TQM & 5S projects.

An effective communicator with strong leadership, coordination, analytical, relationship management and problem-solving skills.

Experience of working under cross-cultural and multi-lingual environments. Competency Purview

Quality Assurance / Quality Control

Managing written procedures for production & process control designed to assure that the products adhere to quality parameters.

On hand experience on UT machines – Einstein-II DGS (shear wave contact), Olympus Epoch-4 (shear wave contact), New tech full body UT machine (immersion transducers technique), EEC – DUT31 coil UT machine

(Straight contact) and GE - SNUP automatic UT machine (Contact TR probe).

On hand experience on MPI machines – Magnaflux, DCM & Diaglo make wet /Dry – Coil, Central conductor, Yoke.

Monitor RT unit – VJ inspection systems and also monitor PT inspection.

Preparing & implementing quality assurance program in line with manufacturing and organizational goals.

Conducting all activities necessary to verify confidence in the quality of the process. Dimensional inspection

(Linear and angular measurements, Thread inspections, Calibrations…. etc.).

Coordinating internal audits as per the schedule, in line with ISO, API and NS1. Ensuring compliance with audit observations for process improvement.

Maintaining quality standards for the product at all stages right from procured material to finished product.

Calibration exposure: - Linear & Angular measurements – Slip Gauges; Tensile test machine -Load cells; Charpy machine – NIST samples; Extensometer – Dial calibrator; Thread working gauges – Master Gauges ……etc TQM, Lean techniques Implementation

Conducting feasibility studies and preparing necessary procedures, guidelines for implementing TQM (Total Quality Management) projects in the organisation.

Leading the implementation of TQM, SPC guidelines with a view to enhancing efficiency levels and effectiveness.

Working towards cost reduction through better work method adoption, total quality approach, failure analysis, optimum resource utilisation and adherence to operational guidelines.

Developing, establishing & implementing technical requirements for achieving good quality and new designs. Process Management/ Re-engineering

Establishing control procedures to monitor the output. Validating performance of those manufacturing processes that may be causing variability in the characteristics of in-process material and the product.

Ensuring process validation by establishing documented evidence and confirming that a specific process consistently produces a product meeting its pre-determined specifications and quality characteristics.

Process control experience: - Welding-Friction, Inertia, MIG, SAW...etc; Forging-Tool joints; Upsetting-Drill Pipes, tubing; Heat treatment – Gas fired Furnace, Inertia, SQF; Machining – Conventional, CNC; Threading – API, water well, High torque connections.

Manufacturing/ Production Coordination

Initiating, implementing, and controlling written manufacturing and processing procedures.

Coordinating in the minimization of performance bottlenecks for achieving high productivity with minimization of men, material & machine. Identifying areas of improvement and recommending process modifications and equipment calibrations to enhance operational efficiencies of machine / equipment.

Planning manpower deployment and managing them effectively for achieving the production targets of plants.

Product exposure: Drill Pipes, Tool joints, Tubing & Casing Pipes, Couplings, Heavy weight drill pipes, Drill collars, Line Pipes, Stabilizers, Water well Pipes, Helical Anchors …etc. Sales & Technical

Reviewing / Preparing technical and commercial offers, Tenders. Liaise with customers related to product queries. Products dealt like Drill string assembly, Fishing tools, Handling tools, ….etc.

Leading the implementation of TRACS (Trader Asset Control System) with a view to deal business effectively.

Initiate, implement, and controlling technical aspects by establish product integration suitable to understand both parties of suppliers as well as customers.

Professional Experience

Since Nov’11, Working with ‘World transload & logistics LLC’ Minneapolis MN, USA as Manager- Quality department (Working since August 2014 at Drill Pipe international / Jindal - Sister company located at Baytown, Texas)

(Is a manufacturer of quality products (Drill pipes, Tool joint forging, Heat treatment & Threading to the energy industry.) &

Noteworthy Attainments

Manager –Quality (Nov’11 to till date)

Reviewing customer enquiries and update the feasibility based on standards and resources.

Essayed a key role by designing the work orders based on resources and standards.

Controlling all test, inspection and in process control activities.

Maintain and update specifications, procedures, work instructions and all other documentation.

Monitoring gauges, instruments usage, calibration and testing equipment.

Undertaking destructive (Tensile, Charpy V-Notch, Hardness, Micro, Macro, Bend test as per ASME-Sec.VIII), non-destructive testing (MPI-Diaglo & Magnaflux, UT-Einstein, Olympus, New tech, EEC & GE, PT and RT – VJ inspection systems), thread inspection (API, High torque connection) and measurement (Linear & Angular) activities.

Following up with regard to Internal/External audits and required documents.

Maintaining API & ISO certifications, Welder and other special process activities, qualifications to both companies at Minneapolis, MN location as well Baytown, TX location.

Assuring all products as per customer requirements (Contract reviews, Welding parameters, Heat treatment parameters, Upsetting parameters, Forging parameters, Threading parameters, Production orders….etc) by maintain the systems in line.

Provide “on hand and expertize ideas as a Level-III” to our sister company “Jindal Tubular USA, MS” by taking care of Plate UT machine (EEC) and Automatic UT machine (GE), X-ray units, and also taken care of quality systems.

Maintain traceability and and process controls by using “SAP” tool by collect the 'parameters and description' and by design the logic. Generate 'BOM' and 'Routing' to the required production orders. Maintain Tracking system at each station by controlling proper traceability of all batch numbers. Since Oct’09 to Nov’11 with Petrostem, Dubai, UAE as Manager-inside sales

(A company, fully owned and a part of Petroleum pipe corporation Group operating in different countries. The group is a supplier of quality products and services to the energy industry. Company provides down hole drilling tools and accessories for rent, sale and lease.)

Noteworthy Attainments

Manager –Inside Sales (Oct’09 to Nov’11)

Reviewing sales data base daily and provide the customer requirements by preparing the quotations based on Stock, and from suppliers quotes as well.

Dealing with customers for status of quotations based on due dates and their importance of product.

Essayed a key role in establishing the tracking system (TRACS) starting from enquiry stage by covering operation, documentation, final dispatch and payments.

Following up technically, commercially for enquiries, quotations, Tenders, supplier certifications and required documents.

Conduct / Arrange inspections for used / due date products.

Update and maintain the Stock items located at different areas.

Arrange / Monitor work orders processing at Machine Shops at different locations. Since Aug’07 to Oct’09 with DPAL FZCO - Soconord, Dubai, UAE as Manager-QA/QC

(An API Q1 certified company, fully owned and a part of Soconord Group operating in different countries. The group is engaged and specialises in OCTG / Line pipe suppliers. About 80% of the Drill pipes manufactured in UAE Dubai are exported)

Noteworthy Attainments

Manager – QA/QC (Aug’07 to Oct’09)

Maintaining close coordination with client, project team and external agencies

Undertaking Critical Shop and Field inspection as well as vendor evaluation.

Followed up with regard to internal/ external audits (API and NS1) and required documents.

Preparing WPS, PQR and WPQ as per ASME Section IX to the Friction Welding, and Hard Banding processes. Also provide set parameters and qualify operators on Heat treatment process.

Ensuring complete prevention of non-conformities and repeated failures.

Undertaken Destructive tests (Tensile, Charpy, Hardness and Bend tests), Nondestructive tests (MT & UT) and inspections (Threads, Hard banding, Welding and dimensional).

Played a major role in securing product approval and certification for Level-3 NS1 by ensuring all quality & inspection requirements are met with regard to new & refurbished Drilling & Well completion equipment.

Registered improvements in productivity by 25% per month by establishing traceability, inventory and preventive actions on non conformances.

Essayed a key role in setting up in-house testing laboratory and reducing products’ testing cost up to 90%.

Developed technical procedures and methods for Mother pipes and Tool joints inline with sour service grades.

Developed inspection procedures for field inspection, repair/refacing of DP2S (Double shoulder) connections.

Successfully established and designed high torque drill string connections named as DPHT. Mar’98 to Aug’07 with Oil Country Tubular Ltd., Nalgonda (Andhra Pradesh, India). Last designated as Plant Engineer-QA/QC

(ISO9001: 2000 certified company, involved in complete manufacturing of oil country tubular goods like Drill pipes, Tubing pipes, Casing pipes, Drill collors, substitutes Plug containers etc) with annual sales of INR 30 Billion. Major customers include ONGC, OIL, SPC, Schlumberger, Halliburton etc.) Noteworthy Attainments

Plant Engineer-QA/QC (May’05 to Aug’07)

Involved in preparing and implementing heat treatment set parameters and process for OCTG products and Engineering components.

Broad management functions including staffing, Planning and administration of Quality Control and Quality assurance departments.

Maintenance of gauge room and calibration of inspection, measuring and testing equipment.

Conducting metallographic and failure analysis and also preparing quality system procedures. Establishing special process and vendors.

Liaising with customers and third party agencies.

Resolving line problems, participating in meetings and also maintaining Minutes of Meeting.

Managing and implementing TQM projects with the aim of enhancing overall process quality.

Optimized existing heat treat cycles to reduce process time by 34%.

Distinction of establishing heat treatment process for bar stocks, Drill collars and Plug containers.

Monitoring and controlling Non destructive testing (NDT) of OCTG products.

Succeeded in establishing software to control the traceability system by TQM approach.

Played a major role in effectuating standards DS-1 critical (Drill stem elements) product for drill pipes. Engineer-Quality Control/ Quality Assurance (Mar’98 to May’05)

Maintaining close follow-up for inspection of:

Incoming raw material and critical items.

Upsetting, heat treatment, threading and welding parameters as per API specifications.

Calibrating thread gauges and all other measuring instruments.

Following up with regard to mechanical testing and machine calibrations as per ASTM and ASME standards.

Monitoring heat treatment processes. Ensuring all necessary specifications are complied with.

Hold merit for bringing about significant improvements with regard to:

Supplier’s performance by highlighting their problems. Thereby accomplished reduction to the tune of 50% of in-process delay times, arising due to incoming material problems.

Inspection system by providing fit gauges rather than measuring instruments. Education

B.Tech. (Mechanical with Industrial & Production Engineering) from Nagarjuna University, Guntur in 1997

(Secured 1st class).

Professional Certifications

Quality Management Systems Auditor / Lead Auditor on ISO 9001:2008 from Nigel Bauer & Associates in conjunction with TUV NORD Abu Dhabi, UAE. Certified by IRCA in March 2009. Certificate No:2009/1102

Certified Internal Auditor Training on Integrated Management Systems (ISO 9001:2008, ISO 14001:2004, OHSAS 18001:2007) from TUV Rheinland at Abu Dhabi, UAE in 2010.

ASNT Certified NDT Level-II in PT, VT and RT from “Curie Institute of Quality and NDT Technology” and

“Industrial quality institute” in 2008 and 2011 respectively.

Certified ASNT NDT Level-III in Method MT & UT on 9/12 & 3/14 respectively. Certificate number 187281.

Courses

Diploma in “Total Quality Management and ISO-9000” from National Institute of Labor Education & Management, Chennai in 2002.

Post Graduate Diploma in Computer Applications from NIT, Hyderabad in 1998 (Passed with distinction).

Diploma in Advanced Mechanical CADD from AUTODESK Training Center, Visakhapatnam in 1999. Seminars

Participated in national workshop on “Metallography for engineers” organized jointly by institution of engineers & Metallography society India on 10th-11th December 2004.

Seminar on Environment, Health and safety conducted by TUV Middle East in Dubai on 2nd April 2008. Personal Vitae

Current nationality : Live in America (H1B Visa valid up to September 2017). Passport Details : J2007225 (Issued at Visakhapatnam. Valid up to 11/04/2020) Driving License Details : 1) DLFAPO2486362003 (Issued at Nalgonda, A.P. Valid upto 2023) 2) 1458575 (Issued at Dubai, UAE. Valid upto 2019). 3) 39065699 (Issued at TX, USA. Valid upto 2017)

Languages Known : English, Telugu and Hindi

References : To be furnished upon request

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