Development Head, NPD, Quality, Process control, Design & Development

GANESAN.S

Head Product Development & Pattern shop

C.I, S.G Iron, Steel & Mn steel, Foundry Exp. E-mail :*************@*****.**.**

Mobile : 995-***-****

Whatsapp: 701*******

SUMMARY :

Looking for Managerial Foundry Industries myself Graduate in Foundry Technology -27 +years Foundry Experience with strong practical result oriented foundry men. Cast Iron, S.G. Iron, Steel, Alloy Steel, Mn. steel, High chrome & Heat resistance steel castings. I have Developed varies types of components like Pump, Valve Body, Earth mover, Railway components, Textile, Windmill, Turbine, Cement Plant, Crusher, Machine Tool, Automobile & Engineering Castings. I have involved myself in all type of activities like Pattern estimation, Pattern design & manufacturing, Gating and Risering, Yield improvement, Process development, Continuous Improvement, Production, QA, Root cause & Fish bone analysis, Heat. Treatment, ISO activity, Materials, Implementation of new technologies, Customer Co-ordination, and Quality etc. To achieve the organization goal and capable of handling a team of Managers, Engineers and operators and work closely with other support function.

OBJECTIVE:

To maintain a challenging position with a company that would value my education, expertise, ability and experience. To work with a team that has a strong work ethic and a safety conscious mindset.

WORK EXPERIENCE:

January 2018 to Till now as " Head (Assistant General Manager) – Product Development & Pattern shop " with Pitti Castings (Pvt) Limited, Hyderabad.

January 2017 to January 2018 as " Senior Manager Design & Development " with OCL Iron and Steels Limited. Bhiwadi, NCR

May 2015 to Jan 2016 as " Senior Manager R & D " with Kirloskar Ferrous Industries Ltd., Solapur

Jan 2012 to Apr 2015 as " Manager New Product Development " with Hinduja Foundries Ltd., Chennai

Aug 2008 to Dec 2011 as “Manager Methods & Development” with Martopearl Alloys Pvt. Ltd. Hyderabad

Apr 2004 to Aug 2008 as “Manager Methods ” with Vignyan Industries Ltd., (A Subsidiary of BEML Ltd., Bangalore), Tarikere, Karnataka.

Nov 2003 to Apr 2004 as “Methods & Pattern shop Engineer” with Shanthi Gears Ltd., Coimbatore

Aug 1992 to Nov 2003 as “Methods Draughtsman” with Lakshmi Machine Works Ltd., Coimbatore.

JOB PROFILE:

Reporting to Plant Head.

Major responsibly for RFQ, New product Development, Methoding, Quality issue, Defect analysis, Pattern design and Pattern shop activities.

Responsible for New Programs as per the Business Plans and to interact with Customer and do follow –up.

Study of new enquiry / accessing product technical feasibility, estimation to submit the Business development for processing of New and respect order.

Prepares Time Line for each program and monitors the same effectively in order to maintain the target date.

Effectively utilizes customer standards and engineering practices on assigned programs.

Using design software like Auto Cad for 2D drawing and Solid works (3D Modelling).

Design of Pattern, Core box, Mould box and other foundry components.

Methoding and gating system used by through Magma 5.3 simulation software.

Pattern making follow up for approved and new vendors to get right time for tool.

And also existing pattern repairing, corrections and modification done by inhouse or out side vendors.

Completion of Sample Development Documentation approval process like PPAP, PFD, PFMEA, Control Plan, Design Reviews etc.

Design and Development of components for Castings from development to up to bulk production.

Analyzing and troubleshooting the problems faced during Product Design & development, Designing, Manufacturing, Trails, and Production.

Designing of Gating and Risering system for new development components.

Ensuring the Trials of new tool received on time and preparing the trial report of all trials for all NPD.

New Product Development, Sample validation & get approval from Customer.

Follow-up and getting approval from sample casting to up to PPAP submission for customer end.

Casting defect analysis. Improvement in existing tooling's.

Ensuring continuous improvement in the in running component & reduce the rejection level.

Increase Yield by improving for existing casting.

Casting Defect analysis, Corrective and Preventive action taken for Internal and Customer Complaints.

Implementation of CIP(Continual Improvement Process).

ISO Documentation & Implementation.

Improving Quality / Productivity / Reliability at manufacturing with continual improvement.

Executing cost saving techniques/ measures and modifications to achieve substantial reduction in O&M expenditures and work within the budget.

Coordinating Molding, Fettling, Quality Control, Purchasing and marketing Person, achieve Perform to schedule goals.

ACHIEVEMENTS OF PITTI CASTINGS:

1.GETS CUSTOMER :

Indian Railway part Traction Transom casting developed and approved 3rd sample.

It is very intricate and fabrication design casting. It is used for Indian railway under carriage items. This item single source of India. Material grade steel and weight 600 kgs.

Developed C.E & P.E barrel casting Twin cavity Tool for improving productivity to meet the customer requirement. Tooling developed in 45 days and First sample validation done in 60days. It is used for railway Engine part and material is steel grade.

Weight range 500 & 600 kgs.

Railway engine part of Stator Frame casting developed First time right casting of soundness and second sample achieved dimension with machine shop requirement. Weight rang around 800 & 900 kgs. Material is steel.

Other GE railway product like Traction link Bracket, Bracket Dog bone, Center block etc developed short period and achieved GE requirement.

High rejection of Running Product of Journal Box and Cover restudy and Methoding fine tuning done. Rejection reduced from 3.5% to 1.5%.

Running item CE & PE barrel face major welding rework in casting. Taken corrective action by fine tuning of risering system. After correction welding rework stopped in casting. Welding rod consumption 50% reduced.

Running S.G iron product of engine part like Frame head & Stator Frame facing high rejection in Foundry & Machine shop. Both item taken back redevelopment and proved less rejection of foundry as well as machine shop.

2Railway part (Webtec):

Axle Box Housing and Axle box cover steel casting developed and suppling defect free casting.

And also, different developed different type of U – Tube castings.

3Railway part (Indian Railway):

Gear Box upper & Lower, Suspension Tube, Control Arm castings with Gray Iron and S.G Iron casting developed and suppling to Indian Railway ( ICF & CLW)

4GE Energy

Windmill part of Pedestal Casting Upper & Lower developed with out riser. Flow off method used instead riser for heavy thickness casting. Here Methoding technique applied and achieved sound casting as per customer requirement. Material Grade S.G iron and yield is 72%.

5ARM STRONG

Pump Top & Bottom casting developed first time right casting with all aspects in 3 models.

Pump casting dual arm with increate profile of suction and exhaust port developed and achieved all customer requirements.

6McWane

Developed Pump body and disc casting 15 items first time achieved all customer requirement without any issue like machining, assy. Etc.

7Flender (Siemens)

Windmill part of Fun Body & Fun Cover developed and supplied 150 sets as per customer requirement. Material Gray Iron and weight 2.7 & 1.4 ton.

New Design of windmill part of Housing & Housing part, Adaptor Flange, Torque Arm Casting developed and supplied first sample defect free castings. Material grade Gray Iron & S.G Iron. Weight range is 1.2 to 4.0 ton.

8BEML

Bracket casting developed and supplied defect free casting.

This casting 100% RT quality. Critical area level –I other area Level 2 requirement.

Continuously 25 casting produced and supplied with 0% rejection.

Material steel grade and weight 750 kgs. It is used for earth mover equipment.

9CATERPILLER

Customer issue of Transmission Case high rejection at machine shop.

Defect analysis made CA done and rejection reduced and controlled without issue.

MAJOR ACHIEVEMENTS OTHER COMPANY:

i.Developed single piece weight 8 Ton steel Trunnion casting for irrigation project used in Nagarjuna Sagar Dam. Fist sample Castings accepted all customer quality requirement.

ii.Yield Improvement of Jaw plate Mn. steel casting provided single riser per casting and increased yield up to 85 %. Previously used four riser per castings.

iii.Anger Steel Casting used BH-50 Dumper for producing major rework in all the castings at Foundry. I have studied and pattern design modified from vertical to horizontal than all rework eliminate at foundry and reduced rejection level from 10% to 2 %.

iv.BL 9H – Swing structure and swing carriage original in fabrication design and along with R&D team study made and manufacturing process converted from fabrication to casting. In that BEML productivity increased and cost also reduced.

v.Cylinder Block casting higher weight reduced in line with Invoice weight. ( Weight reduction in Bunch, Riser and Casting )

vi.Yield improved 2 % for Running Cylinder block and Cylinder head Castings. (Weight Reduction in Bunch and Riser for Redesign of Running system)

vii.Cylinder Head Casting Productivity increased to double the production. (Cyl. Head Casting number of cavity increased from 2 to 4 for redesigned the existing pattern)

viii.TM Case casting Foundry rejection reduced in 1.6 % to improvement action taken in process

ix.Designed special profile mold box for reduction in sand weight (sand to metal ratio ) in Na bake sand.

x.Developed Jaw plate Mn. steel casting provided single riser per casting and increased yield up to 85 %. Previously used four riser per castings.

PROFESSIONAL EXPERIENCE SUMMARY:

i.Methoding of new castings such as Risering and Gating system.

ii.I am having experience gating system and Risering design of Steel, Gray Iron and S.G iron casting.

iii.Knowledge of magma simulation software.

iv.I am also involved in estimation of cost of castings, cost of patterns and cost of development charges for submitting quotations against enquiries from Customers.

v.Experience in No back, Co2 and green sand molding process.

vi.Experience in Arpa, IMF Fast Loop Line, Hand Molding and High pressure molding line.

vii.Knowledge of in planning, melting, moulding, core shop and process control in foundry.

viii.Knowledge of process control parameters and sand properties.

ix.Experience in root case analysis, analytical and systematic problem solving skills.

x.Co-ordinate with Production team to productionize new parts smoothly.

xi.Having experience man management and ISO/TS system knowledge.

xii.Have Knowledge of cost deliver.

xiii.Design of Patten and core box and Prepare Pattern and Core box drawings.

xiv.Designing the Pattern and core boxes using Solid works.

xv.Mould, Splitting, Core cavity splitting from the casting model using Solid works

xvi.Surface Modeling and Assembly using Solid works.

xvii.Design of Gating and Running system drawings using Auto Cad

xviii.Design of mould boxes and Fabrication drawings using Auto Cad.

xix.Knowledge of NDT Techniques in RT / UT / MPI / DPI.

xx.Pattern Modeling, Core cavity, splitting and mold cavity to developed from Casting Model.

xxi.Products: Valve Body, Automobile, Earth Mover, Railway, Engineering, Cement Plant, Power plant, Wind Mill, Turbine, Machine Tool and Textile application casting.

Products weights: 150kgs to 7500kgs.

DESIGN AND DEVELOPMENT SKILLS:

i.Design and Development of components for Castings from Automotive for Cylinder Block, Cylinder Head and Transmission Case, Earth Moving, Engineering, Wind Mill, Power plant and Cement Plant, with sound technical knowledge.

ii.Analyzing and troubleshooting the problems faced during Product Design & development, Designing, Manufacturing, Trails, and Production.

iii.Design and Manufacture of Sand Mould Castings.

iv.Design and manufacture of Jigs and Fixtures for Foundry.

v.Design of Gauges and Implementation suitable required Dept. for Core shop, Molding line, Fettling and Final Inspection.

vi.Experience and exposure of sheet metal fabrication and techniques.

vii.Estimation and costing of foundry Tools like Pattern, Core boxes and Fixtures.

viii.Experience and knowledge of GD &T.

ix.Good Experience in 2D drawings using Auto cad.

x.Experience 3d models using Solid works.

xi.Experience of PPAP Documents like Technical review process, Process Flow Diagram (PFD), PFMEA, Control Plan and PSW (part Submission Warrant) of NPD items.

xii.3D Part models with casting and machining configurations.

QUALITY SKILLS:

1.Handling of all Quality Assurance related matters in Foundry & customer end

2.Daily Monitoring of Final Inspection with final inspectors/layout inspectors.

3.Casting Layout Inspection Plan & Status.

4.Analysis of Internal & Customer end Rejections on daily, weekly & monthly basis & taking corrective/preventive actions.

5.Handling of customer complaints and resolving the same to their satisfaction levels

6.Rework & Rejection finalization, Decision on deviations, Root Cause analysis of non-conformances & implementation of corrective/preventive actions decided.

7.Implementing 7 QC Tools [Histograms, Pareto Charts, Cause and Effect Diagrams, Run Charts, Scatter Diagrams, Flow Charts, Control Charts

8.Team Building CFT and GEMBA Concepts.

9.Improving Quality / Productivity / Reliability at manufacturing with continual improvement & Kaizens.

10.Casting defect analysis. Improvement in existing tooling's.

11.To attend and Involving daily rejection Meting at shop floor.

12.Maintaining MIS day wise rejection and Monthly report of Item wise, defect wise like Percentage and tonnage wise report Prepare.

13.Monitoring and Establishing process during Product development stage.

14.To prepare SOP for Approved production items.

15.Knowledge and Experience in ISO, TS and EMS.

16.Knowledge of OHSAS and 5S.

17.Identifying scope for modifications in process for controlling & reducing costs per unit.

Profession Strengths :

*Plant Administration *Tooling Expertise

*Costing & Planning * Manpower Planning and Budgeting

*Performance Appraisals * Staff Recruitment & Training

*Problem Solving *HR Policies & Program development

*Job Analysis / Evaluation * Grievance Resolution *Employee relation * Expert of Design & Development

* Expert in Methoding * Expert Quality & Process

* Using QC Tools * Expert of Quality analysis

EDUCATIONAL QUALIFICATION:

1. Graduate in Foundry Technology from Indian Institute of Foundry man, Kolkatta.

2. Diploma in Mechanical Engineering from Coimbatore Institute of Technology, Coimbatore.

3. I.T.I in Draughtsman Mechanical from Sree Narayana I.T.I, Madurai

PROFESSIONAL QUALIFICATION:

1.Computer Aided Drafting (Auto Cad)

2. Solid works – 3D Modeling software

COMPUTER PROFICIENCY:

Auto Cad, Soild works, OPEATING SYSTEMS Windows 98 Xp Windows 7

MS OFFICE 2007 Excel, Word, Power Point, Picture Manager

Paint, Adobe Photoshop

PERSONNAL DETAILS:

Father’s Name : K. Subbiah

Date of Birth : 25.04.1967

Marital Status : Married

Nationality : Indian

Languages Known : English – Read, Speak, Write

Tamil – Read, Speak, Write

Telugu – Speak

Kannada – Speak

Hindi - Beginner and manage

Address : 37, Muthalaman Koil street,

Avaniapuram,

Madurai - 625012

Tamilnadu. India

Place : Hyderabad

Date : 12.01.2022 (S.Ganesan )

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