QUALITY ASSURANCE/QUALITY CONTROL & BUSINESS EXCELLENCE

An abroad experienced Bachelor's Metallurgist, ambitiously aspiring to managerial assignments to contribute significantly to the continuous growth of the steel organization by passionately improving product quality with integrity. Offering comprehensive metallurgical knowledge with superior analytical; innovative problem-solving skills to drive excellence for the greatest success of the QA/QC dept. & to achieve enormous profitability. PROFESSIONAL SYNOPSIS:

Dynamic, visionary, ambitious, creatively intelligent, versatile, resourceful, team-spirited, & competent professional offering more than 14 years of insightful experience in QC, QA & prod. dept. in steel/SS Companies.

Currently, passionately spearheaded the “SQM dept.” with the supreme aspiration of superior product quality as a

“Production Quality Engineer” in “Titus Industrial-USA” at the supplier’s site in Rajkot-MIDC.

With supreme determination, achieved 1st class in every stage of academic during schooling, diploma & B.E. in Metallurgical engineering (Pune city) in spite of doing a part-time job after school/college.

Influential QA leader with a proven track record of strategic QA vision, quick delivery, and demonstrated ability to inspire/mentor quality assurance teams to implement the latest QA programs.

Deft in emphasizing the importance of Quality with integrity by constantly reviewing, updating, and retuning the production process for enhancement & optimizing resources; capacity utilization; escalating productivity; operational efficiencies; while curtailing costs & expenses across organizations.

Brilliantly establishing and meticulously implementing Quality policies, SHE policies & statutory-regulatory requirements, etc. to comply with national/ international std. e.g. ASTM/EN/DIN/IS/ISO standards as well as customer’s specification for achieving best practices during the production and testing process.

Proven ability by constant perseverance to direct and improve in-process compliance by monitoring processes, identifying defects carrying out for failure & rejections. Innovating/implementing new methods/various techniques for defect/deviation prevention, system improvement, cycle time reduction for improving work tasks, entailing identification of opportunities, analysis of data, and pre/post audits.

An extraordinary blend of leadership with in-depth knowledge of steel/alloy steel/SS making through EAF/LRF/CC/Ingot/Heat treatment/Hot rolling route. Steel pipe (LSAW, HSAW, ERW) manufacturing as per API 5L. Stainless steel wire manufacturing through solution annealing/pickling/cold wire drawing/strand annealing route with properties improvement by metallurgical changes during each process of steel/alloy steel/SS.

An effective communicator with excellent management skills, acting as an escalation gate to resolve critical issues, possesses strong analytical, problem-solving & organizational abilities. PROVEN EXPERTISE AND PROFICIENCY IN OCCUPATIONAL CONTOUR: Prashant Shankar Kshirsagar

: +91-839******* : +91-932*******

: adhaud@r.postjobfree.com : prashant3183

: Kshitij building, Flat no.1, Survey no.16/3, Near Aryan Complex, Ambegaon pathar, City-Pune, State-Maharashtra, India, Pin Code- 411046

: linkedin.com/in/prashant-kshirsagar-0668b123

PROFESSIONAL CHRONOLOGY:

Titus Industrial-Dallas USA, Rajkot MIDC-Supplier location Dec’19 – July’20 Production Quality Engineer

Key Responsibilities:

Intelligently directed the Quality Controller team to execute all prodn & quality activities at the supplier’s plant.

Thoroughly studied Titus PO for all quality requirements & prepared action plans for smooth execution in prodn.

Strategically deployed the Quality controller team by preparing a shift schedule for execution of process and product inspection for current manufacturing products at the supplier’s two plants at different locations.

Identified and effectively implemented due diligence to conduct regular audits at different stages of the process such as Mill Material, In-process, and Final inspection stage & to evaluate the effectiveness of product outcome.

Regularly dealt with the Supplier & Third-party testing agency to execute an inspection and testing of products under Titus witness e.g. OES inspection, Chemical testing, Mechanical testing, etc. as per std. testing frequency.

Extensively reviewed & validated FMTR reports from suppliers & upload them into the Oracle NetSuite system.

Proactively resolved technical queries & quality problems, that occurred during the pre-production or production stage in collaboration with Engineering (R&D) team-USA and local testing laboratories in India.

Thoroughly worked on Pre-Shipping Inspection of product and container generic templates per product family.

Carefully reviewed and validated all QC inspection & testing reports and uploaded them into Oracle NetSuite system for top management review and approval process.

Helped in the resolution of aftersales quality issues by analyzing through ‘8D report’ & implemented “CAPA”.

Proposed creative suggestions and monitored supplier's corrective action plans for long term improvement.

Comprehensively prepared SOP’s like “Paint adhesion by tape test on paint coated material”.

Provided technical support on product development & constantly kept Global Supplier Quality Director, Prodn Manager, Procurement & Logistic dept. informed about any issues which may cause quality or compliance issue. Nevatia Steel & Alloys Pvt. Ltd., Tarapur-MIDC April’15 – Oct’19 Senior Manager (Quality Assurance Department)

Key Responsibilities:

Passionately spearheaded the QA dept. for non-destructive & destructive tests by working effectively on QA mechanisms for two different plants i.e. plot no. G5 & G24 in Tarapur-MIDC.

Brilliantly established new wet-chemical lab as per IS 228 std. (‘C’& ‘S’ element by combustion & other elements by gravimetric & volumetric analysis) by taking all quality & safety measures with the help of the QA team.

Stringently adhered to quality compliance of incoming/raw materials, consumables & packing material by careful inspection as per SOP. Meticulously assisting with suppliers on raised complaints during supplier visits.

Thoroughly studied manufacturing feasibility of new enquiry & proactively provided feasibility reports to the customer by sending APQP, PPAP, or filled questionnaire & production trial conducted for review & approval.

Extensively studied customer’s requirements from sale order & effectively communicated these expectations with Prod./QA people by preparing QAP in a clear & concise manner to follow it rigorously during the production run.

Relentlessly complied with the quality of the product during the in-process & final stage by vigilant inspection of product and process at all required stages with the help of the process control team by inculcating production dept.

Precisely conducted complex product PMI inspection & surface examination of wire under a stereomicroscope.

Tightly controlled NC product & achieved consistency in quality by constantly reviewing & updating the process.

Meticulously analyzed in-process/final rejection & customer complaints by doing brainstorming with the team, implemented immediate containment action & further root cause analysis by gathering info from 7QC tools, 5-why analysis & 8-Discipline method, and advised CAPA as per trial results to avoid recurrence of rejections.

Regularly prepared & updated PFMEA/Control plan for each cust. complaint/rejection for further improvement.

Ensured timely dispatches of the mtl. by promptly providing a test certificate as per EN 10204-3.1 & packing list.

Practically conducted i) MSA on measurable properties to ensure %R&R <10% & ndc>5 ii) Attribute MSA to ensure effectiveness 90% on all surface defects iii) SPC study to ensure Cp & Cpk 1.33 as per defined frequency. Did extensive analysis in case of any deviation observed after conducting the exercise.

Pioneered & provided comprehensive metallurgical/technical guidance to prodn for best practice implementation.

Precisely prepared all SOPs for all quality testing/inspection methods & enforced to follow it strictly in operation.

Timely ensured NABL calibration/servicing of both plant all equipment & measuring gauges every year.

Monitored & controlled quality parameters of effluent generated in ETP with regards to Ph, COD, O&G & BOD.

Intensively prepared & updated HIRA, Aspect/Impact, SMP/EMP report regularly & effectively implemented all actions decided for all significant ratings identified points for operational safety.

Regularly conducted a thorough internal audit for various dept. as per the audit plan by providing GP, PI & NC.

Visited different customers for attending complaints, gathered samples for further root cause analysis & “CAPA”.

Diligently planned for the achievement of Quality; SHE & IMS objectives through Balanced Score Card (BSC) on monthly basis and discuss the same among the team members for further course of action on targets.

Provided powerful/inspirational thought-provoking training to all employees by video presentation & interaction.

Effectively presented Quality dept. performance in terms of Quality KPI in half-yearly and yearly MRC meeting in front of top management in the conference room.

Honestly done yearly appraisal & recommended the promotion to an employee as per their annual performance. Almost all employees got promoted in both plants after appraisal & recommendation. Qatar Steel Company, Qatar country Dec’13- Feb’15

Melter: SIEMENS VAI-EAF (Steel Making Department)

Key Responsibilities:

Diligently assisted to furnace in-charge to run smooth operation of EBT furnace by dynamical execution of all prodn activities very promptly i.e. arrangement of all consumables/raw material, scrap bucket charging, melting, refining, bath temperature measurement, bath/slag sample analysis, ladle bottom addn/arrangement & heat tapping.

Rigorously followed & developed synergy among the team to follow/execute all operating, safety, environment & quality procedures throughout production activities.

Recorded highest heat tapping in every shift by dynamic execution & persistently diligence of all activities.

Keenly carried out a routine inspection of the furnace, identified abnormality in f/c or process & immediately reported to implement appropriate/prompt corrective action to avoid/reduce risk to the person/f/c operation.

Innovatively suggested modification of EBT sand storage container & reduced efforts & saved time by 3min.

Efficiently executed all furnace shutdown activities from f/c shell removing until new f/c shell replacement.

Handed over the shift with complete/concise information daily with next shift operators about f/c operation.

Precisely prepared & sent daily prodn log sheet & a monthly graphical analysis for top management review. Bekaert Mukand Wire Industries Pvt. Ltd., Lonand-MIDC May’11- May’13 Senior Process Engineer (Technical Department)

N V Bekaert SA., Belgium country (Abroad Training) Sept’11- Aug’12 Senior Process Engineer (Technical Department)

Key Responsibilities:

With a supreme aspiration, attended one year abroad training in the mother plant of “N V Bekaert SA” (Belgium)

& successfully handled various projects and training sessions with the commendable dedication of learning.

Significantly contributed to Standardize Product & Process parameters & Technology transfer between European and Indian Mfg. Plants & passionately acted as a pivotal point between Indian & European business units.

Successfully initiated ‘Kaizen’ as a project leader & developed ‘Long Bearing Length Pressure Die’ in Belgium.

Diligently worked as a project leader for B-machine development after successful availing Belgium training.

Meticulously prepared job cards with all standard operating instructions & successfully achieved desired product quality for every running program by deeply studying projects, process & product requirements.

Newly developed/standardized size-wise machine speed & load chart for B m/c for fast/quality production.

Successfully executed cost-saving techniques to increase profits & reduced O&M expenditures e.g., SS wire rod entanglement problem reduced by installing a smooth discharger at the payoff section & reduced entangled scrap.

Comprehensive failure analysis was done by using SPC, 6σ, QC tools for all rejections/scrap & successfully solved problems by suggesting new ideas and innovative solutions for process enhancement.

Successfully handled & installed ‘Online-Eddy current testing m/c’ during wire drawing by conducting trials.

Proactively reduced process/product quality problem by ensuring no stoppage of the production process.

Vigilantly done s/f & metallographic examination of SS wire under Stereo & Metallurgical microscope.

Effectively coordinated with Bekaert Technology Center (Belgium) & another key learning plant to get guidance on the process and product developments made in their plant & implemented it horizontally.

Effectively presented project performance on regular basis in front of top management. Welspun Corp Ltd., HO-Mumbai May’08 - April’11

Assistant Manager (Quality Assurance & Technical Services Department) Key Responsibilities:

Coherently asked & get clarified all new requirements of the customer by thoroughly studying each customer’s enquiry by complying with ISO, ASTM, BS, EN, DIN, API 5L specifications & checked production feasibility.

Precisely prepared & submitted all Quality documents to the customer e.g., Raw material-technical Specification, Manufacturing procedure specification & Quality assurance plan for review & approval for each inquiry & order.

Supremely received domestic & international customer’s orders on most of the submitted Quality documents.

Comprehensively provided filled Questionnaire with all supporting documents for various customers.

Excellently developed a centralized e-library system for all standards & regularly checked new version.

Cautiously attended kick-off meetings & teleconferencing with interplant for various orders as and when required.

Effectively coordinated with Sale’s & Purchase dept. for technical queries & provided Metallurgical guidance.

Appropriately maintained, periodically reviewed & initiated purchasing of all required new version standards.

Newly developed systematic filing system by using ‘5S’ techniques for all docs/standards & files. Mahindra Sanyo Special Steel Pvt Ltd. Khopoli-MIDC Feb’06 - May’08

(Formerly-Mahindra Ugine Steel Co.),

Senior Engineer (Quality Assurance Department)

Key Responsibilities:

Superbly controlled online process deviation by effectively conducting daily process inspection/audit with exceptional attention and persistently hammering production people to work within a specified standard for EAF, LRF, Bottom pouring (B.P.), Continuous casting (C.C) in the Steel Melting process as a process shift in-charge.

Newly developed monthly process control report system with a graphical presentation by summarizing all observations, that are recorded online in every shift & addressed to the top management for immediate “CAPA”.

Appraised for development of new B.P. mould segregation system according to surface observation judgment from inner/outer side, which helps to significantly reduce surface defects of ingots & its potential rejections.

Successfully reduced UT rejection by 20% being as a key member of the UT rejection project.

Diligently spearheaded various projects e.g., 1) Reduce high superheat in CC 2) Minimize chemistry deviation.

Extended special attention to executing containment action on rejected products e.g., Anti-flaking cycle to steel.

Reduced rejection with the greatest surveillance & improved process by implementing CAPA by team efforts.

Delivered & arranged technical training programs as a training leader for QA team members in every week. Uttam Value Steel Ltd. (Formerly-Lloyds Steel Industries Ltd.), Wardha Feb’05 - Feb’06 Graduate Engineer (HRM-Quality Control Department) Key Responsibilities:

Precisely conducted all Mechanical tests with super-fast execution of all activities in front of T.P.I agency on flat- rolled coil samples such as Tensile test, Compression test, Bend test, Impact test at room/sub-zero temperature as per ASTM A370 standard & Hardness test such as I) Brinell Hardness Test (ASTM E10) II) Rockwell hardness test (ASTM E18) III) Vickers hardness test (ASTM E92), etc. of different grades/sizes of steel samples.

Vigilantly conducted surface inspection, NDT testing, inclusion rating (ASTM E45), grain size measurement

(ASTM E112), and microstructure examination under stereo/metallurgical microscope of steel sample.

Successfully developed a new method of sample polishing for metallographic testing and saved time by 20 min.

Assisted in the in-house calibration of all testing machines & equipment in the HRM-QC lab.

Effectively online controlled & rigorously followed detailed EAF, LHF & CC process inspection by instant online reporting of deviation/NC to the top management to achieve output product properties as specified in std.

Delivered extraordinary results by showing the tremendous potential of handling multiple activities in every shift.

Submitted an absolute observation of process inspection report & controlled NC by asking an immediate CAPA.

Promptly prepared Test certificate & updated all Quality test reports in the SAP system. CAREER ACCOMPLISHMENTS:

An absolute reduction in Cost & considerable Profit improvements: A) Nevatia: i) Reduced total cost of packing by changing packing pattern & packing material & saved more than 11,58,168/-INR per year ii) Total cost of Quality inspection has been reduced by developing in-house lab testing facility e.g. PMI testing (saved 5,00,000-6,00,000/-INR per year) iii) Reduced purchasing cost of lab material e.g. a) Saved 30,600/-INR on platinum crucible b) Saved 1,15,860/-INR on weighing scale c) Saved 14,500/-INR on NABL calibration/servicing of equipment d) Saved 26,325/-INR in lab furniture B) Bekaert: i) Reduced cost of measuring pins & saved 700-800/-Euros etc. by developing the product, excellently negotiating & greatly persuasive on the quoted prize with suppliers & finding lessor cost supplier. Enthusiastically developed New System at Nevatia Steel: Customer complaints reduced by using 8D methods, developed new practices/system, modification & effectively implemented CAPA e.g. i) Sample preservation system of each delivery started for future delivery reference & investigation of customer complaints ii) Drawn wire surface soap residue measurement system developed iii) Application of all QC tools e.g. Pareto chart, Fish Bone diagram, Check sheet, Why-why analysis, etc. started in regular practice iv) Attribute MSA practice started for each visual s/f defect v) Effective communication register started for in-process team & customer complaint vi) Monthly internal verification/calibration of all laboratory instruments/equipment started vii) Grade mixed-up detected case recording & analysis started viii) Plant trial monitoring record started with all information for better judgment ix) Precise density measurement by using Baume hydrometer started x) All tensile testing m/c speed standardized at 12.5mm extension of crosshead per minute xi) Lab renovation was done & ‘5S’ system established xii) The corrosion test started as per IS 10461-part 2 xiii) Moisture content test started xiv) Spring passivation test started xv) All label preparation started in excel software for accuracy xvi) Hot water tank prepared for complete removal of degreasing chemicals from wire surface xvii) Wet chemical analysis lab developed with all required chemicals and equipment e.g. Fortin’s Barometer for accurate atmospheric pressure measurement xviii) Using Sodium based lubricant i.e. Vicafil TN 1164G in final pass started for uniform soap coating. ix) Systematically modified in-process inspection format to capture every small observation & deviation for future reference and analysis. Persuasively improved/shaping up of existing System: A) Nevatia: i) Systematically prepared/modified inspection checklist to get all information & desired results e.g. RM/In-process/Final inspection, TC, plant trial records, 8D report, MRC ppt, Dock audit & rejection analysis, PFMEA, REACH-RoHS & Conflict Mineral declaration, etc. ii) Comprehensively prepared SOP’s e.g. all mechanical testing, internal/external calibration of equipment/gauges, MSA, Attribute MSA, Soap residue measurement & SPC to improve work practices iii) Tensile testing machine upgraded with computerized operating software. iv) Customer complaint reduced by modifying Process route, changing inspection frequency, conducting new trial & improving existing practice. B) Qatar Steel: i) Suggested different materials & cover of carbon injection sandblast rubber hose to avoid frequent leakage. C) Bekaert: i) Bright bar inspection practice improved with several suggestions & displayed OPL at the workplace. Lab operational Safety enhanced at Nevatia Steel:

i) Lab testing safety improved with “zero accident” by providing Safety Guards/PPE’s/training. ii) Regularly reviewed & updated HIRA/Aspect Impact/OCP/SMP-EMP by taking all necessary actions & displaying OPL. iii) First aid medicine kit purchased for the wet chemical lab. iv) Whistleblowing system started for Forklift signaling & safe operation. v) Forklift, container, sling belt inspection checklist prepared for strict inspection. Innovatively done “Kaizen-Change for the Better”:

A) Nevatia: i) Metal boom stand prepared for effective inspection of wire in packing. ii) Reverse Torsion test started by doing modification in old machine iii) Bend Test Machine speed has been reduced to 1 sec per bend & cylindrical supports to the bending arm guide height has been redesigned as per IS1716. iv) Innovatively developed the 17/7pH same wire size mandrel with the improved tensile strength by giving precipitation hardening heat treatment to withstand wrap test load according to the requirement of ASTM A370/ ISO 7802/EN 10270-3 standard. v) The wrap test machine modification has been done by reducing the distance at a 15cm gap from the stationary to the movable gripping device for rigid fixing of the mandrel. B) Bekaert: SS wire rod entanglement problem reduced by installing a smooth discharger for auto hitting the stuck winding layer at the payoff section results in the reduction of entangled scrap & downtime of the m/c. ii) ‘Long Bearing Length Pressure Die’ developed in Belgium for improvement in the soap lubrication system Creatively done out of box thinking to implement “Poka-Yoke-Mistake proofing” at Nevatia Steel: i) Wooden spool bore diameter go-no-go gauge prepared from acrylic plastic ii) Machine wise Cast & Helix inspection board prepared iii) Size measurement on micrometer stand iv) Yield/proof strength measurement started by fixing micrometer at the center of wire while tensile test. TRAINING:

Sr.

No.

Training Subject

Training

Duration

Name of Institute/Company Location

Period of

training

1 Systematic Problem Solving in Mfg. 1-week Mahindra Institute of Quality Nashik Dec-2007 2 Project Management for Technologist 1-week Stanwick management Belgium Oct- 2011 3 Six sigma: Green Belt 2-weeks N.V. Bekaert SA Belgium Nov-2011 4 Eddy Current Testing on SS wire 2-weeks N.V. Bekaert SA Belgium July-2012 5 Die shop: Reworking of TC/ND/PCD 2-weeks N.V. Bekaert SA Slovakia Feb- 2012 6

Industrial shop floor & technical

training on wire drawing practices

1-Year N.V. Bekaert SA Belgium

Sept’11-

Aug’12

7

Magnetic Particle Testing (MT)-

Level II

3-days

Insight Quality Services-ISO

9001 & NCB (ISNT) certified

Pune June 2013

8 Ultrasonic Testing (UT)-Level II 3-days

Insight Quality Services-ISO

9001 & NCB (ISNT) certified

Pune June 2013

ACADEMIC CREDENTIALS:

AWARDS & EXTRA CURRICULAR ACTIVITIES:

With supreme determination achieved distinction in Diploma engineering & won “Sir Ratan Tata Scholarship”.

Won the prize in the Bumper round of “Executive Talent Search competition” as organized by the Tarapur Management Association (TMA).

Comprehensive training given in organization like 1) Stainless steel 2) Quality Inspection 3) Attribute MSA 4) Strand Annealing process 5) Problem solving through 7 QC Tools 6) APQP 7) SPC etc. Published on Slide Share website i.e. https://www.slideshare.net/PrashantKshirsagar1/ & received many likes/comments.

Successfully organized the “Quality Month” celebration program in Nevatia Steel from 2015 to 2018.

Enthusiastically played adventurous sports like Bungee jumping, Paragliding, River rafting, Kayaking, Trekking, Zip lining, climbing wall, Riding the ropeway line, and Rappelling sports, etc. IT SKILLS:

Operating Systems: Windows 98, 2000, 2007, 2010

Software Skills: Microsoft Office 2019 (Word, Excel, Outlook, PowerPoint Presentation, MS Paint), Google drive, ERP, Oracle NetSuite, DropBox, SAP, Cloud-based Slack, Google calendar, Photo/Video Editor, Skype, Microsoft Teams, Zoom, Adobe Acrobat 7/Pro DC, pdf Editor, Internet, etc. PERSONAL DETAILS:

Languages Known: Marathi, Hindi, English

Passport No.: J5036799 & valid till 2021

Marital Status: Married

Date of Birth: 31st July 1983

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