VISHAL S. KALE

IWT Certified Mechanical Design Engineer

: +91-992******* / 952-***-****

: adc91b@r.postjobfree.com

:Vishal Kale

SENIOR LEVEL ASSIGNMENTS

~ Design Engineering Welding Operations New Product Development Project Management New Product Development ~

A versatile, high-energy professional with the distinction of executing prestigious projects of large magnitude within strict time schedules, cost & quality

Industry Preference: Manufacturing / Service / Design Consultancies

PROFILE SUMMARY

A competent professional with 15+ years of experience/exposure in:

Design Engineering Project Management Welding Operations

Quality Assurance Inspection and Testing Product Design Calculation

New Product Development Value Engineering Change Management.

New product Design & Development.Product design idea creation, concept development. Product Specification and Design calculation based on Product standards.Product BOM preparation. Prototype manufacturing and prototype testing. Pilot Batch execution with the help of Mfg. Preparing the product specification and catalogue. Prepare the Product Manufacturing procedures and Implement them in production line.Training to production peoples for product manufacturing and testing.Prototype validation by testing and calibration.

Proven acumen in planning & controlling the welding operations including welding of machinery & optimization of process parameters to maintain quality and achieve operational excellence

Efficient in ensuring the execution of inspections and tests as per appropriate Inspection & Test Plan (ITP)

Delivered dynamic breakthrough in providing technical inputs & engineering support to the team from conception to completion of project and extracting programmes for drawing detailing.

Proficient in process equipment design and its approval, preparation of product assembly instruction sheets, welding procedures/ Procedure Qualification/Welder’s qualification and its approvals under Third Party inspection as per ASME as well as EN

Demonstrated excellence in developing, qualifying and approving procedures, establishing & approving techniques, interpreting codes, standards, specifications and procedures

Comprehensive knowledge of ASME SEC VIII, II, IX, V, AWS & ASNT Codes / Specifications on pressure part design, Welding & NDT functions. Flange standards like ASME B16.5, EN1092-1, BS10, AWWA stds.

Expertise in planning design & development operations and conceptualizing & effecting process initiatives to enhance efficiency

Skills in problem solving coupled with confident decision making for enabling effective solutions leading to high customer satisfaction and low operational costs

NOTABLE ACCOMPLISHMENTS ACROSS THE CAREER

Accomplished the International Welding Technologist certification ( IWT) from IIW.

Proven acumen in:

oDesigning Six Sigma experiments to achieve most desirable factor values using Minitab software and work Samples prepared to control the DFT range for painting process.

oDesigning of experiments techniques used to control the fusion weld penetration inside the Vortex flow meter

Played a key role as part of inspection procedures and quality plan in ASME “U” stamp quality audit for ENPRO Industries; prepared welding procedures and approvals for ASME.

Steller in THERMAX Surface preparation & coating standard preparation with design of experimentation

Merit of visiting Germany for “Pressure Equipment Directive” training of the Vortex Flowmeter for KROHNE MARSHALL in 2008 and achieved underlined results:

oPED certification of the product under TUV as a Responsible Design Engineer at Pune Manufacturing Plant

oProduct was approved as PED with all required design, assembly instruction sheets and inspection procedures

oProduct design calculation as per ASME and other international stds.

oCritical Welding and machining process in product assembly were successfully setup in Pilot Batch Testing

oPrepared welding procedures and qualifications using manual as well as semi-automatic machine

Instrumental in creating special fixtures to achieve the Fusion Welding of Vortex Flow Meter using tool room that augmented productivity by twice than the manual one

Attended:

oTemperature Product trainingat Emerson Rosemount at Minneapolis, US in 2012; the training was used for working on the global product engineering support such as engineering modification and product support, failure analysis and welding process setups.

oAdvance Excel Tool training at Emerson to make testing tool of Model Code Conversion Tool and Product Cost Tool; instrumental in making Thermowell weight & volume for all variants with standard and non-standard option ready to use Rosemount temperature group.

Demonstrated skills in:

oFilling 4invention disclosures at Emerson. Preparing Incremental improvement tools for engineering support work using excel to improve work productivity and effectiveness. Rewarded with the award and gifts for New Innovation ideas on the existing Products.

CORE COMPETENCIES

Developing the conceptual design of new products including handling requirement analysis & prototype planning, studying specifications and modifying / upgrading designs for approval of 1st sample & final part accordingly. BOM preparation.

Drafting welding procedures, qualifying and approving techniques while interpreting codes, referring to standards, specifications and procedures; defining particular NDT methods, techniques and procedures

Preparing the product as per customer requirements and translating design model using various quality tools; working in synergy with clients / manufacturing facility to implement value engineering initiatives for standardization.

Managing complete new product development with accountability of fulfilling key requirements viz. features, cost, conceptualisation, prototype development, validation, testing, approval, development as per client specifications

Identifying areas of bottlenecks & breakdown and non-conforming products; taking steps to achieve zero accident & customer complaints through the application of troubleshooting tools like root cause analysis.

Designating the particular NDT methods, techniques and procedures to be used and utilizing appropriate NDT methods for executing the project

Monitoring prototype development with respect to cost, resource deployment, time over-runs and quality compliance.

Coordination with vendor for product design and development.

ORGANISATIONAL EXPERIENCE

Since Oct’15 till date : Radix Electrosystems Pvt. Ltd. Navi Mumbai as Assistant Manager-Product Design Flow

Role:

Flowmeter Product development &Calibration lab setup.

Turbine flow meter Product, Electromagnetic Flowmeter design and development. Product design idea creation, concept development. Product Specification and Design calculation based on Product standards.

Product BOM preparation. Prototype manufacturing and prototype testing. Pilot Batch execution with the help of Mfg.

Preparing the product specification and catalogue.

Prototype and Pilot Batch calibration and testing with 5 point and 10 point calibration.

Communication/Follow-up/ Discussion with Vendor for any Special Part or By-out

Presales support for sizing of flow product and providing technical solution by applying appropriate product and application engineering support and technical discussion with presales. Support involves material selection for flowmeter and size

Follow-up and Communication discussion with factory for resolving issue.

Prepare the Product Manufacturing procedures and Implement them in production line.Training to production peoples for product manufacturing and testing.Prototype validation by testing and calibration.

Feb’11 – Sept 15 : Emerson Innovation Centre, Pune as Senior Engineer – Product Design

Role:

Design calculation for Thermowell design using ASME standards ASME PTC 19.3

Idea generation concept on Thermowell – Patent activity.

Ideation in filing invention disclosure.

Design Sustaining works involves Thermowell and transmitter drawing preparation and modification by closely working with EMERSON Business Unit in US.

Application Engineering - Proposal activity based on RFQ (customer request-Application), supporting for Temperature Sensor as above.

Failure analysis works for Thermowell product site complaints.

Supporting Manufacturing in preparation of Welding Procedure Qualification Record (PQR) Welding Procedure Specifications of thermowell.

Thermowell Engineering Model Code Conversion Tool and Product Cost Tool; instrumental in making Thermowell weight & volume for all variants with standard and non-standard option ready to use Rosemount temperature group.

New Innovation on Idea’s which can be used for internally of the customer or which can be as patent and also by cost cutting. (Products or any other ideas).

Jan’07 – Feb’11: Krohne Marshall India (Forbes Marshall), Pune as Engineer (Design & Development)

Role:

Sales support for WORK special quotations. ( WSQ’s ). Handling the nonstandard cases for the EFM as well as Vortex Flowmeter. Checking the design feasibility. Design Calculation to check the feasibility of the modification suggested by Sales and Customer for non std cases. Design feasibility cases also involves the design calculation as per ASME std, special welding testing, NDT testing. NACE Corrosion testing for Oil & Gas. Drawing generation and System BOM codification.

Closely worked with KROHNE Germany for technological transfer projects in India for Vortex Flow meter. ( PED and IBR )

Imparting training to welders to ensure quality work.

Executing measures and effective techniques to augment efficiency in welding & fabrication operations/facilities.

Closely working with Industrial Tool Room division for various fixture development of product manufacturing.

Examining field failures and executing preventive measures to eliminate the same.

Entrusted with the responsibility of:

oComputing stress as per ASME / PED & IBR standards

oPerforming Non Destructive Testing/ Inspection, identifying areas of quality failures and taking steps to rectify the same.

oDrafting process-engineering & layout drawings and detailing of equipment after gathering product specifications.

oManaging product safety approval, prototype testing & development, technological transfer works with Business Units.

Analysing testing requirements as per customer specification;

Creating dimensional components with technical drawings of components or small sections of a product using AutoCAD programs

Managing:

oWelder’s continuity record andpreparing weld maps specific to products.

Testing PMA material for PED; ensuring ASME material approval process with pressure part design as per ASME standards

Supporting Manufacturing in preparation of Welding Procedure Qualification Record (PQR), Welder qualification record and Welding Procedure Specifications.

Analysing field failures and designing preventive measures for eliminating/reducing the same with help of DT & NDT methods

PREVIOUS EXPERIENCE

Jul’06-Dec’06: Suzler India Ltd., Pune as Quality Assurance Engineer (Welding & QA Role)

Role:

Demonstrated excellence in WPS / QAP preparation for various projects.

Receipt material identification. Stage inspection like Mock up assembly of column internals like Trays panels chimney trays & distributors, collectors, Feed piping.

Visual & Final Dimensional inspection after Final Welding. Structural inspection of Beams, columns, support & locating grids. Final packing inspection.

Structural elements like mock up assembly of column internals (trays panels chimney trays & distributors)

May’05-Jun’06: Enpro Industries Pvt. Ltd., Pune as Quality Engineer (Welding Engineer & QAC Engineer)

Role:

Experience in review of piping layout, isometrics, GAD.

Distinction of working for ASME audit of ‘U’ stamp certification for Pressure vessel & company had received ‘U’ stamp certification from ASME. Awareness of international standards, engineering calculations

Understanding the customer specification given by sales and worked on Inspection documents required for submission.

Generating and maintaining inspection & test reports like daily inspection, final class, client, manufacturer data and final documentation.

Skids engineering drawing review, checking & Inspection involvement.

Actively involved in preparation of WPS and witnessing PQR, WPQ & their preparation.

Accountable for preparing list for WPS & WPQ & Welder’s continuity record, weld maps.

Distinction of welding inspection & coordinating between production & QAC to resolve quality related issues.

Demonstrated excellence in QAP & inspection Test Procedure preparation for ASME & Non ASME projects.

Instrumental in preparing Radiography offering & LHS for piping as per P ID & Film interpretation; LPT testing.

Successfully reviewing of documentation with TPI like LRA, Moody International, BV and EIL.

Distinction of working for ASME audit of ‘U’ stamp certification for Pressure vessel & company had received ‘U’ stamp certification from ASME.

Nov’03-Apr’05: Thermax Ltd. (Contract), Pune as Senior Engineer (Project, Welding&QAC)

Role:

Preparation Of Welding Technology Sheets & weld maps.

Closely worked with Project department for Quality works inspections in various projects.

Accountable for preparing Paint maps preparation & Painting inspection covering DFT, WFT, Holiday testing, Adhesion test, Salt spray testing, Testtex tape method for surface profile.

Distinction of designing experiments based on the Six Sigma to achieve most desirable factor values which will control the DFT range for Painting process.

Actively involved in reviewing of documents with TPI like GE Power projects, Moody International.

Instrumental in preparing Thermax surface & painting standard (TSPS-2)

Inspecting:

Pressure parts like pressure vessels, D/E, nozzles, piping, tube sheets, hydro / pneumatic testing

Visual and final dimensional after final welding, Beams, columns, support and locating grids

CERTIFICATIONS

IWT Certification from IIW, NDT - RT Level II-Interpretation,PT Level II, MPI Level II, Welding Inspector (ASNT) from Insight Quality Services, Pune.

TRAININGS

Design of Experiments in FORBES MARSHALL & EMERSON

Value Engineering

DFMEA (Design for Manufacturing) in EMERSON

Geometric Dimensioning for Stack up Analysis in EMERSON

Problem Solving Techniques

Creativity & Innovations

Presentation skills

Fish & Team Building

Planning and Organising skills

Achievement Motivation

ASME Code Awareness

PROJECTS

Title: Radix Electrosystems Pvt. Ltd.

Period: Oct’15 – On going

Description: New product development for Turbine Flow meter and Electromagnetic Flow meter series with complete design and development up to productioning from start. All Manufacturing procedures, tooling and lab test setup for testing and calibration.

Role:

Flowmeter Calibration lab development.

Prototype Design& development, Drawings and BOM preparation. Manufacturing and testing.

Product manufacturing procedures, catalogue and manual preparation.

Engineering Support to Presales for inquiries.

Manufacturing engineering support.

Title: Krohne Marshall & Emerson

Period: Jan’07 – Feb’11

Description: PED & IBR product design approval for Vortex Flowmeters for European and Domestic one. Complete Welding support includes documentation, testing approvals for Flow Meters. Weld & product failure analysis projects for Flowmeter & Thermowells.

Role:

Carried out technical study on controlling the delta ferrite in stainless steel casting of variable area flow meters

Designed experiments for controlling the welding parameters to improve the weld penetration

Involved in:

oWeld design documentation and failure analysis for surface temperature measurement type of Thermowell

oThermowell Model Conversion, Weight & Volume (New product Development).

Title: ENPRO

Period: Jan’07 – Feb’11

Description: ASME “U” stamp quality approval for Lube Oil & Seal gas Filter systems. A Quality & welding approval works dosing systems (Reliance-Patalganga), repair & modification of separators (ONGC BHS platform through Hyundai Industries - S. Korea Offshore Project) for ASME “R” stamp, Pump & Drum Skid (L & T Powai –Bunduk, Offshore), Storage Tanks for L & T Baroda. Includes Welding support includes documentation

Role:

Administered L & T project for special material welding projects

Title: THERMAX

Period: Nov’03 – Apr’05

Description: Quality & welding approval works Exhaust Gas Boiler for GE, Waste Heat Boiler for Bagfas Lurgi, Hot Oil Heater for ZEECO Betara Indonesia, Waste Heat Boiler for JSC Taif, Circulation Pump Skid / Fuel Gas Skid for Shell-Gabon. It includes Welding support includes documentation.

Role:

Involved in design of experiments for improving the surface preparation & coating techniques of boilers and heat exchangers MINITAB software used for analysis

ACADEMIC DETAILS

2005 P.G. Diploma in Boiler & Process Equipment Design & Engineering from Vishwakarma Institute of Technology, Pune.

2003 B.E. (Mechanical) from R.M.C.E.T. Ratnagiri, University of Mumbai.

Others:

Diploma in Mechanical Engineering from Board of Technical Examination, Mumbai in 1999

ADDITIONAL SKILLS

AutoCAD, Proe, Solid works., Oracle BOM.

Knowing of Office Package: Microsoft Word, Microsoft Excel, Microsoft PowerPoint and Microsoft Outlook Express

STRENGTHS

Self-Starter Passionate about improvement and excellence. Take initiative to learn the new and understand the old.

Driven by the team's pursuit of success and perform where needed; whether leading or following.

Keeps interest in learning foreign languages in future.

PERSONAL DETAILS

Date of Birth: 27th April 1979

Address: Runal Apartment 3, Flat No 3, Bijlinagar, Chinchwad, Pune – 411033, Maharashtra

Languages Known: English, Hindi and Marathi

Nationality: Indian

Gender: Male

Martital Status: Married

Dependants: Spouce, Two children, Mother and Father. ( Pune )

Job location preference Pune, Maharashtra, Anywhere in India.

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