Quality Engineer

Sachin Anna Punekar

Mobile – KSA: +966-*********, India: +91-950*******, Email: ********@*****.***, Skype ID: sachin.punekar1982 Seeking assignments in Quality Assurance & Quality Control with a growth-oriented Organization Personal Details

Present Address Saudi Iron & Steel Company (Hadeed), Jubail city, KSA Date of Birth 27th September, 1982

Gender Male

Marital Status Married

Nationality Indian

Language Known English, Marathi & Hindi

Passport Number H2069955

Permanent Address House No. 1147, Bhekarainagar (Papdewasti), Post-Phursungi, Tal-Haveli, Pune-412 308, India

Snapshot

An efficient, methodical and skilled Quality Assurance Engineer with 10+ years of experience who has considerable experience of developing and implementing effective Quality control processes and structures in a manufacturing and corporate environment.

Presently associated with Saudi Iron & Steel Company (Hadeed), Jubail City, KSA as Quality Control Engineer.

Possessing a good understanding of the essentials of safety and Quality. Ensured that manufacturing or production processes meet international and national Standards.

Strong customer service experience, and a background of achievement in supporting all levels of management & working to set schedules and deadlines.

Expertise in devising and establishing a company's Quality procedures, Standards and Specifications.

Adept at setting up and maintaining controls and documentation procedures.

Experience in carrying on investigations of internal rejections, reworks and implementing CAPA on NC Products.

Conversant with ISO/ TS 16949:2002 and ISO 14001 (EMS) activities.

Knowledge of Indian & International Standards like ISO, ASTM, BS, JIS, DIN, GOST & SON. Exposure in top management meetings, monthly performance & review meetings.

Skilled in reviewing Customer requirements and ensuring the compliance.

Experience in working with purchasing staff to establish Quality requirements from external suppliers. Possesses strong inter-personal and leadership skills. Areas of Expertise

Planning and implementing analytical method validation as a part of technology transfer from research level to scale up level at manufacturing site.

Reviewing the specification inline with the respective pharmacopoeia and make the equivalence study.

Looking after analytical method transfer from site to site and to make sure that later has ability to implement it and its effectiveness too.

Co-ordinating regulatory affair department for effective filling of different dosage form and resolving there queries with respect to product formulation and analytical method.

Preparing SOP`s for various departments and effective implementation of same by conducting internal audits.

Monitoring, review & handling the change control, deviations, incidence report and variations.

Maintaining calibration status for all the instruments.

Responsible for monitoring and maintaining Quality and compliance targets.

Monitoring and auditing of products to ensure high Standards of Quality.

Ensuring products comply with legislation and Quality assurance codes.

Ensuring that all QA Tests are carried out on time and in full. Competencies

Quality Management

Quality Control

Documentation (ISO)

Safety (EHSS / SHEMS)

Housekeeping (5S)

Training & Development

Quality Assurance Audits

Quality Reviews

Operational Effectiveness

Process Control

Testing & Inspection

Customer Complaint

Employment Profile

September 2014 till date at Saudi Iron & Steel Company (Hadeed), Jubail City, KSA as Quality Control Engineer

Identifying and evaluating Quality problems, suggesting solutions and taking suitable corrective measures by coordination with QC SV, QC Manager, QA & T&I.

Analyzing the customer complaints and implement suitable corrective actions by coordination with QC SV, QC Manager, QA, Production SV & T&I.

Coordinate with Steel Plant In-charge to ensure suitably good quality of billets are received by RMLP and give feedback for bringing improvements. Coordinate with RM/BM In-charges to take feedback regarding material being processed. Based on the performance the improvement actions to be initiated along with concerned agencies. Coordinate with test house for test results and subsequence process improvement. Coordinate in the activities of product development and trial production.

Coordinate with PSD & SBU for diversion of nonconforming product and PSD-Scheduling for possible salvaging of nonconforming product.

To take decision of material HOLD by inspector during the course of online inspection with QC SV and witness the re- inspection or make close observation of representative samples and release the suitable material for dispatch by QC manager involvement.

Establish standards for any new facility, process, practice & develop the Quality parameters accordingly for RMLP.

Communicate with different vendors and suppliers for any improvement in the process parameters related to Quality issues.

Prepare Monthly, Quarterly & Yearly statistical Quality performance reports which will reflects target versus actual figures.

Communicate with ISO Coordinators & internal auditors for ISO documentation related to RMLP QC.

Must be familiar with Health, Safety & Environment policies of the company & follows EHSS objectives& Department objectives.

May 2013 to July 2014 at Jindal Stainless Limited (Jajpur, Orissa) as Manager-Quality Assurance

Handling overall Quality (SMS) Lab activities like Chemical Analysis by Spectrometer, Raw & In process material analysis by XRF, Meltdown Heat Analysis, Audits, ISO documentation, QMS, Calibration & maintenance of laboratory equipments & manpower management. Managing & maintaining laboratory equipments and calibration & maintenance activities

Monitoring Maintenance, Calibration & Standardization of instruments like OES ARL 3460, LECO TCH 600, LECO TC 600, LECO CS 230 & ARL XRF Advantex for accurate test results in time & providing required spares for the same.

Reporting chemical analysis, slag analysis & following of IGC practice (practice A, C & E) as per customer requirement.

Monitoring the testing activities as per standard operating procedures (SOP), analysis of results and final reporting as per customer compliance.

Supervising laboratory activities & arrangement of chemicals, primary & secondary standards, spares & consumables for timely analysis of samples. Planning and following up of Third Party Analysis for Meltdown heats.

Conducting joint analysis with third parties by understanding their requirements & accordingly handling the quality issues.

Forecasting of Inventory requirements, raising PR & their follow-up with Purchase & Store Departments.

Imparting theoretical & on job training to subordinates regarding Technical, Safety, 5S & Communication Skills for their personal development. Implementing & following up of IMS (Integrated Management System).

Monitoring all ISO documents like Registers, Formats, Quality Plans, SOP's, Primary & Secondary Standards & records of sample analysis, training, calibration & maintenance of laboratory instruments. Dec 2010 – Nov 2012 at African Steel Mills Nig. Limited (Lagos, Nigeria) as Assistant Manager, Quality Control

Handling all quality related activities like Mechanical Testing, Chemical Analysis, Incoming, In process & Final Inspection, Hot Rolling Process Control, Internal Audits, ISO documentation & QMS

Developing, Implementing and Monitoring Key production Unit, Quality Control Systems and Procedures ensuring Compliance with all Internal and External Customer requirements

Ensuring;

o Visual inspection & chemical testing of incoming material like Scrap, Ferroalloys & Petroleum products. o Routine Maintenance of Spectrometer, Sample preparation machine, UTM machine and other laboratory equipment’s. Mechanical Testing of Steel Bars by UTM Machine o Chemical Analysis Test Results of Heats in Production by samples are carried out in Optical Emission Spectrometer (CCD based) & Strohlein Apparatus in wet analysis laboratory o Metallurgical Analysis of products including Macro and Micro etching o process testing like Slag Analysis in chemical lab o Visual Inspection to monitor & control the metallurgical defects in the product o Process Control Parameters of Melting in Induction furnace, Heat Treatment of Billets / Ingots, Casting of Steel, Rolling of Billets / Ingots to steel Bars

o Identification and Traceability of all products at In process and Final Stage.

Arranging and monitoring the Calibration of Laboratory equipment’s.

Keeping the track of procurement & issue of required material through Navision system. Coordinating with SON (Standard Organization of Nigeria) for Product compliance as per their specification. Keeping track of non complying products.

Handling customer complaints & giving corrective actions accordingly by proper investigation and root cause analysis.

Implementing and monitoring ISO 9001-2008 & OHSAS 18001-2007 system procedures.

Having awareness of TMT rebar manufacturing technology complying BS4449 Standard.

Ensuring that health and safety guidelines are followed by QC personnel.

Developing a highly motivated, well-trained quality staff capable of meeting the short and long term staffing requirements of the department & ensuring Departmental Trainings.

Key Highlights:

Improved the Yield Strength of D bars from (380 – 410) N/ mm2 to (420 – 460) N/ mm2 by stabilizing the chemical composition of Steel grade 420.

Instrumental in the reduction in rejection due to High Carbon from 4.36% to 0.99 % in Steel grade 420.

Reduced the Crack Billet production during casting from 2.57% to 0.74% in Steel grade 420 by modifying the Casting Process Parameters.

Implemented QC related practices (documentation) during ISO 9001:2008 & OHSAS 18001:2007 certification audit (In year 2011) in order to get the same.

Handled SON audits by compliance to SON standard in order to get MANCAP Certification (2011 & 2012).

Developed the Key users for Quality Clearance in the newly installed manufacturing module of Microsoft Dynamics Navision 5.0 (ERP system) (In year 2012).

Established skilled Spectro operators by giving trainings on newly installed Spectro machine. July 2005 – Dec 2010 at Mahindra Ugine Steel Company Limited (Khopoli, Maharashtra) as Senior Engineer, Quality Assurance

Testing & Process Control-Melting & Rolling:

Managing all quality testing related activities like Metallography (Microscopic Analysis), Mechanical testing, Chemical Analysis by Spectroscopy & wet method, Customer Complaints & QMS.

Monitoring heating cycle & charging practice of ingot, bloom in chamber furnace & WBF.

Deciding soaking temperature & time for ingots, billets and post treatment after rolling.

Performing final inspection of as rolled, hardened and tempered, normalized and annealed material.

Preparing advance process intimation report, action plans for new development & in case of deviations & making failure analysis for major non conformities.

Monitoring magnetic particle testing & ultrasonic testing of rolled product.

Monitoring and study the effect of deviations on final quality of the product.

Controlling Cost of Poor Quality (COPQ). Working as the team member of Continual Improvement Project (CIP).

Conducting layer audits in blooming mill, bar mill, forge shop and conditioning shop.

Ensuring that the product meets all customers compliance.

Working as the team member of Yield Development Projects and Waste Management. Key Highlights:

As a leading team member in ‘Waste Management Team’, saved in lacks by re uses of abrasive cutting wheels for QC sample cutting (In year 2007 / 2008).

Reduced the rejection due to Pearlitic Microstructure from 2.4% to 0% in ball bearing Alloy Steel grade SAE 52100 by modifying Spherodise Annealing Cycle (In year 2007 / 2008).

Reduced the rejection due to internal Ultrasonic Defects from 3.7% to 0% in alloy Steel grades 42Cr4Mo2 & 40Cr4C, by modifying Post Treatment Cycle (In year 2009).

Knowledge Domain

Mechanical Testing: Impact, Yield, Tensile, Jominy (Hardenability) & Hardness Testing.

Metallographic Testing: Inclusion Rating with K4 method as well as Worst Field Method, Banding, Grain Size and Decarb level & also checking of Ball Bearing Steel as per SEP 1520, tests like Fracture & Blue Fracture test, Macro etch testing of as cast bloom samples and finish product samples.

Preparing Field Failure Analysis, Root Cause Analysis (RCA), investigation reports & giving corrective & preventive actions accordingly in case of internal & external complaints.

Non Destructive Testing (NDT): Knowledge of Eddy Current Testing, Ultrasonic Testing, Magnetic Particle Testing & Dye Penetrant Testing.

Gas Analysis: Analysis of H2, N2 & O2 gases present in the Steel.

Spectro Analysis: Analyzing Chemical Composition of an alloy Steel by using Optical Emission Spectrometer (PMT based).

Chemical Analysis: Chemical Analysis of Ferroalloys & Raw material like lime, dolomite, coke, graphite, CPC, furnace slag, fluorspar, furnace oil, DRI & sponge iron.

Knowledge of Steel Quality Standards like ASTM, AMS, IS, BS, JIS, DIN & GOST.

Preparing all necessary documents for TPI & reviewing daily clearance of the material.

Ensuring the calibration activity & maintaining records for Laboratory Equipment’s.

Customer Complaint: Experience of handling customer complaints, preparing investigation reports, CAPA, 8D & FMEA reports accordingly for major quality issues.

Preparing product quality plan, control plans & contract reviews for new product inquiry.

Having an awareness of QMS, APQP, 7 QC Tools, PPAP, SOPs, SPC, MSA and TQM.

Audit: Experience of conducting layered audit, system audit, product & process audits.

Basic awareness of Six Sigma & 5 S tools and techniques. Education

B.E. (Metallurgy Engineering) Government College of Engineering, Pune, Maharashtra in 2005, Scored 58%.

Higher Secondary Certificate (HSC) from Pune Board, Maharashtra in 2000. Scored 66%.

Secondary School Certificate (SSC) from Pune Board, Maharashtra in 1998. Scored 73%. Project & Training

Project on “Polymer Quenching of an Aluminium Alloys” at Vanaz Private Limited, Pune.

Vacation Training during third year of degree at Bharat Forge Limited, Pune.

Training on “Product Part Approval Process” (PPAP) at Q – Pulse Services, Pune.

Training on “Email Communications & Business Standards”, ASM, Lagos, Nigeria.

Training on “Thinking Styles – Interpersonal skills”, ASM, Lagos, Nigeria.

Training on “Statistical Data Analysis”, Hadeed, Jubail Industrial city, KSA. IT Skills

Computer Exposure:

o Microsoft office, C Programming

o Able to work with Quality Module in SAP & Microsoft Dynamics Navision 5.0 (ERP system). o Awareness of Quality Module in PDI (Production Data Information) system References: Available on Request

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