Quality Assurance Control

CURRICULUM VITAE

PERSONAL DETAILS

Name : Derek Joseph Malone

Address : **** *** ***** ***** – Orlando Florida 32836

Contact Telephone Number : 312-***-**** U.S.A – 082******* South Africa

Email Address : n041r4@r.postjobfree.com

Date of Birth : 6th November 1957

Place of Birth : Newcastle, England

ID : South African

Passport : British Passport & U.S.A Green Card

Age : 53 years

Marital Status : Married

Leisure : Golf, Horse-Riding, Music/Guitar & Motorcycles

QUALIFICATIONS

1. Diploma Production Management (DMS)

2. Master of Science Degree - Metallurgical Engineering

3. B. Comm. Degree (Business Management Major)

4. Completed 2 subjects towards B. Comm. Honors (Business Management)

.

COURSES ATTENDED

1. Industrial Relations

2. NOSA Industrial Safety Advanced (Cum Laude)

3. Quality Control Advanced (CSIR)

4. Effective Executives (1st Class Pass)

5. St John’s First Aid

6. Heat Treatment Training (Advanced) – Germany & U.S.A

7. Advanced Drivers License

8. Skippers license sea going vessels

9. Assessor programme – tertiary education

PROFESSIONAL INSTITUTES

1. SAIF (South African Institute of Foundrymen)

2. Life member Princeton Global International

OTHER

1. Appointed as National Examiner for 3rd year Metallurgy (1983)

2. Appointed as part-time lecturer at Technikon Witwatersrand now University of Johannesburg. (UJ) (1981-1989)

Subjects: Physical Metallurgy (1st and 3rd year) & Quality Control (3rd and 5th year –

Master level))

3. (Awarded Student Prize by Foseco for subject distinctions)

4. Registered Assessor – Higher Education

EMPLOYMENT HISTORY

SUMMARY

1990 to present Metrite Metallurgical Services – Metallurgical Consultancy Service. Managing Director

1983 to 1990 Sandock Austral (Alrode) – Metallurgist/ Head of Heat-Treatment

1982 to 1983 General Electric Co Foundries – Quality Assurance Metallurgist

1980 to 1982 Steelwheel & Axle (DORBYL) – Works Metallurgist

1975 to 1980 Standard Brass Iron & Steel Foundries – Senior Metallurgical Technician

1990 to present

METRITE METALLURGICAL SERVICES

Metrite Metallurgical Services was established in 1990 with the view of providing a metallurgical service to the foundry, forging, heat treatment, mining, agriculture and general engineering industries. These services include: -

* Full Mechanical Testing

* Research into new production processes

* Casting simulation modeling

* Corrosion testing

* SEM

* Supplier audits

* Failure Investigation

* Supply of steel forgings, castings and round bar as a broker

* Non-Destructive Testing

* Sand Testing

* Heat Treatment Trials

* Heat treatment procedures (times -temperatures) atmospheric calculations

* Welder qualification

* Metallographic interpretations

* Short course presentation – the courses offered include – foundry technology – heat treatment – forging – sand technology – core making – melting – aluminium and copper technology – production metallurgy – quality control – stainless steels – tool steels. These courses have been offered to steel suppliers (wrought), foundries forge shops and heat treatment personnel

As principal member I have personally been involved in the following:

• Commissioning of gas carburising and gas nitriding heat treatment plants. This involved plant outlay – furnace design – process control – atmosphere calculation and operation parameter selection and implementation.

• Sales and marketing of services offered.

• A sub contractor for commercial heat treatment for the mining, automotive and general engineering industry specialising in the thermal treatment of gears for light and heavy duty transmission systems.

• Problem solving for aluminum extrusion, casting and heat treatment problems

• Managing and operating carburising, nitriding, hardening, tempering, salt bath heat treatment plants when required to stand in for staff shortages and new component development.

• The design and commissioning of a heat treatment plant for the manufacture of ground engaging parts using walking beam, mesh belt and rotary hearth furnaces.

• The design, commissioning and writing up of all thermal process specification for applicable alloys of and quench and temper plant at a steel supplier for in-house and commercial heat treatment.

• Investigating the cause for the fire damage of a quenching plant – reporting on the factors that caused the fire for an insurance claim. Rectifying these critical issues and upgrading the pant to the point where it was efficiently operating. This included the writing up of operating procedures and instituting statistical process control.

• Optimization of a ring rolling plant in terms of correct heating parameters prior to forging, selection of input material defect levels, selection and modification of hardening and tempering parameters.

• Manage both metallurgical and mechanical laboratories for commercial work.

• Metallurgical advice on material selection and applicable heat treatment process.

• Welding procedures and welder qualifications.

• Lecture, examine and conduct research at a prominent South African university in a senior capacity.

• Research and development of Thermit rail line welding.

• Assessing and verifying operation efficiency of a waste to energy plant prior for export.

• Hydraulic failures and research on wear products.

• Reverse engineering of imported products, selecting processes and material to suit local supplier limitation. Sourcing local suppliers which include – plant audits, supplying technological assistance to suppliers that require such input.

• Project management of new casting development from drawing to final heat treatment state. Ensuring conformance to customer requirements.

• The financial aspects of the company i.e. cash flow, capital planning, debtors, creditors and finally the drawing up of the financial statement with the assistance of the accounting officer.

• Statistical process control implementation in foundries, heat treatment and steel suppliers.

• The supply of steel castings, forgings and round bar as a broker in stainless steel, cast iron, carbon steel, low alloy steels and tool steels.

• Being on retainers for three heat treatment plants – these have included gear manufacturing, steel supplier and commercial heat treatment.

• Over 500 forensic metallurgical reports and court case representation as a specialized witness.

• Project management of critical mine boring cutters and transmission components from material selection, heat treatment and quality assurance.

• Consulting and refining thermal processing procedures for two major international tool steel heat treatment plants that use salt bath and vacuum heat treatment equipment.

• The training of foundry, forging and heat treatment personnel on Statistical Processes Control techniques with an emphasis on microstructure interpretation.

• Metrite Metallurgical Services has a base of over 150 clients. A list of these clients and testimonials will be forwarded upon request.

• Span of control – 2 metallurgists – 3 technicians – 15 operators

1983 – 1990: -

Sandock Austral – Gear Ratio Engineering

Business Type: Manufacturing of transmission, steering and suspension systems for heavy-duty transport and military vehicles. Gear systems for rolling stock, aircraft fuel systems and helicopter gear boxes.

Position: Metallurgist/ Heat-Treatment Manager

Responsibilities:

1. General management functions (planning, organizing, leading, budget development and control)

2. Plant throughput and production targets

3. Specify casting defect levels according to ASTM levels for military components and rectification procedures

4. All aspects of heat treatment including gas carburizing, gas nitriding, quenching and tempering and induction hardening

5. Sales and marketing of services offered

6. Plating shop (copper, cadmium and phosphating)

7. Painting Shop – military components to MIL standards

8. Company welding procedures and testing of military suspension components and amour plating. Group welder qualifications

9. All material selection and substitution for new projects – reverse engineering

10. Metallurgical/mechanical laboratory

11. Destructive and non-destructive testing and evaluation of results

12. Chemical Laboratory

13. Internal and External failure investigation (transmission, suspension, engine)

14. Customer and Client liaison

15. Supplier of round bar, castings and forgings auditing

16. Marketing: Heat Treatment and Metallurgical services

17. Metallurgical trouble-shooting related to engineering functions

18. Quality control, house-keeping and safety

Heat Treatment Processes Included: -

*Gas Carburising (pit, muffle and sealed quench)

* All conventional thermal processes

*Gas nitriding

*Hardening and tempering

*Annealing, stress relieving and spheroidising

*Sursulf – tufftride baths

*Induction, hardening, tempering and brazing (200kw 9,6kHz med. freq.)

*Press quenching (numerically controlled)

*Solution treatment and age hardening of Aluminum castings and extrusions

*Cryogenics

Materials included: -

Low and medium carbon steel, low alloy steel, stainless steel, tool steel, cast iron and aluminium/copper based alloys.

SPAN OF CONTROL:

2 Supervisors, 1 Foreman, 1 Metallurgist and 10 Operators

1982 – 1983: -

General Electric Company - Foundries

Business Type: Foundry involved in casting of SG, Grey Iron, Aluminium gravity die and investment casting for the railway and general engineering industry.

Position: Quality Assurance Metallurgist.

Responsibilities:

1. Implementation of QA Programmes

2. Formulation of all departmental operating procedures (aluminium- cast iron, SG iron, investment melting)

3. Destructive and non-destructive testing

4. Formulation of all heat treatment – welding and foundry procedures

5. Implementation of process control techniques (SPC)

6. Metallurgical evaluation of suppliers & sub-contract heat treaters

7. Metallurgical problem solving i.e. casting (Cast iron, SG & aluminium) defects, welding & heat treatment

8. Customer liaison and technical complaints for SG, cast iron and aluminum products

9. Supplier inspections – audits

10. SPC implementation

SPAN OF CONTROL:

3 Inspectors, 2 Technicians & 1 Operator.

1980 – 1982: -

STEELWHEEL and AXLE

Business Type: Forging of round bar, axles and hollows. Assembly of wheel systems for the locomotive/rolling stock industry.

Position: Works Metallurgist.

Responsibilities: All Metallurgical Activities within the company, which included the following:-

1. Welding and formulating procedures

2. Heat treatment specifications and control

3. Chemical and Metallurgical labs.

4. Material selection and local material substitution

5. Sub-contractor evaluation –audits – wheel quality verification

6. Forge quality control and metallurgical investigations/problem solving

7. Wheel/axle assembly using SPC techniques

8. Destructive and non –destructive testing and result evaluation

9. The company also offered a metallurgical consultancy service which was my direct responsibility – Finance, Marketing and Consulting

These services included the following: -

*Failure investigation and report writing

*Destructive and Non-Destructive testing

*Photography and Micrography

*Heat Treatment and welding procedures

*Chemical analyses and Mechanical Testing

*Interfacing with clients

SPAN OF CONTROL:

2 Supervisors, 1 Technician & 2 Operators.

1975 – 1980: -

Standard Brass Iron & Steel Foundries

Business Type: Foundry involved in melting, casting and heat treatment of ferrous and non-ferrous based materials.

Position: Senior Metallurgical Technician.

Responsibilities:

1. X-ray testing of safety critical castings and interpretation of radiographs

2. Dye penetrant - Eddy current – Magnetic Particle testing

3. Green sand testing and control

4. Resin sand testing and control

5. Metallurgical Laboratory - sample preparation, etching and hardness testing

6. Correct application of thermal processes to all casting types with emphasis on castings used in the railway industry (wheels, side-frame, knuckles and bolsters)

7. Mechanical testing and certification of railway products according to specifications and interfacing with South African Transport authorities

8. Mechanical testing and reporting for all castings requiring such testing

9. Steel shot testing and control

10. Casting weld procedure development and metallurgical verification

11. Metallurgical failure investigation related to melting, feeding systems, heat treatment and sand –mould defects.

SPAN OF CONTROL: 4 technicians and 2 operators

• Please note that references will be supplied upon request

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