Quality Control Process
Resume:
Anil Kumar Chikkam
*** ******** ******, *** *, Malden, MA 02148
****.*******@*****.*** Mobile: 617-***-****
SUMMARY
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I am a Metallurgical professional with 3 years of experience in the automotive field, with proven and demonstrated experience in metallurgical lab, heat treatment, quality, process & material development. Ability to work in a team environment or as an individual. I have proven and demonstrated my ability to learn quickly, be a self-starter and blessed with a multitasking ability to develop and implement mission critical projects on time and on budget.
I have supported internal and external stakeholders from different parts of the world. Mentored and coached less experienced Engineers to reach their goals. I have excellent presentation skills, communication, mentoring, coaching and consensus building skills.
EDUCATION
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Masters of Technology (Metallurgical & Materials Engineering) April- 2008
Indian Institute Technology (IIT), Kharagpur, West Bengal, India, 9.15 / 10 CGPA
Bachelors of Technology (Metallurgy & Materials Technology) April- 2006
M.G.I.T (Mahatma Gandhi Institute of Technology) affiliated to JNTU
(Jawaharlal Nehru Technological University, Hyderabad), 80.31%
Research: Surface engineering of Interstitial Free Steel
Awards: All India 1st prize in paper presentation on super alloys
Publications:
1. Anil kumar Chikkam, Manojkumar Debnath, J. Dutta Majumdar, S.Mukharjee and I. Manna, “Surface Engineering of Interstitial Free (IF) Steel”. Surf. Coat. Technol (in communication)
2. Anil kumar Chikkam, Manojkumar Debnath, J. Dutta Majumdar, S.Mukharjee, D.Bhattacharjee and I. Manna “Surface Engineering of Interstitial Free (IF) Steel”. (Poster presentation in NMD (National Missile Defense), Delhi, India)
3. Anil kumar Chikkam, Manojkumar Debnath, J. Dutta Majumdar, S.Mukharjee, D.Bhattacharjee and I. Manna “Laser Surface Cladding on low alloy Steel”. (Poster presentation in NMD (National Missile Defense), Delhi, India)
COMPUTER SKILLS / EQUIPMENT KNOWLEDGE
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MS Office Applications: MS Word, MS Excel, MS Power Point
Programming Language: C
Documentation: ISO standards
Skills: SAP Material Management
• Experienced in Maintaining Organization Structure (Enterprise Structure) related to Materials Management (MM), Production Planning.
• Experienced in Configuration of Procure to Pay Process by defining Document Types, Number Ranges, Pricing Procedure, Message Determination, Inventory Management (IM), Automatic Account Determination (Materials Management).
Equipment Knowledge:
o Scanning Electron Microscope (SEM)
o X-Ray Diffraction
o Optical Microscope with Image analyzer
o Digital Rockwell & Vickers Hardness Tester
o Brinell & Micro Vickers hardness tester
o Millipore Analysis
o Universal Testing Machine
o Profile projector
o Gauges
EXPERIENCE
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TVS- Sundram Fasteners Limited, Hosur Title: Dy. Manager (R& D/Metallurgical Lab)
Sundram Fasteners is a flagship company of US $ 5 billion TVS Group¬¬, manufacturer of auto components through Powder Metallurgy (PM) & Cold Extrusion (CE) route. First Indian company to be ISO 9000 certified. All operations are ISO 9000, IS 14001 & TS 16949 certified. Winner of TPM Excellence / TPM consistency award.
Key Deliverables/ Responsibilities:
• Handling Metallurgical/quality activities related to Testing and Heat Treatment (Carburizing, Carbonitriding, Induction hardening, Steam treatment, Annealing & Normalizing).
• Conducting Metallurgical Failure Analysis.
• Troubleshoot process and product for corrective action and preventive maintenance utilizing Root Cause Analysis Methods (8D).
• Internal & External (Suppliers) audits as per CQI-9.
• External auditor for 5 different plants.
• Ensure suppliers are able to meet performance, quality, cost and delivery of components
• Assist suppliers to select, develop and validate the processes, equipments and tools.
• Establish NDT processes (Eddy current inspection, Magnetic Particle inspection) to ensure that defective parts should not reach customer.
• Established NDT processes in 3 different plants.
• Develop and maintain Process Control Plan and PFMEA that will improve productivity & customer satisfaction.
• Develop and maintain work instructions and manufacturing operating procedures.
• Providing technical inputs viz. product and process related to facilitate achievement of production targets and new product development.
• Analyzing various processes / applications and recommending process changes to initiate cost savings and enhancing operational efficiency.
• Work in-house with other departments to achieve cost-reduction, quality improvement and efficiency.
• Practicing TPM (Total Productive Maintenance) activities for improving effectiveness of equipments-processes and incorporating quality maintenance.
• Led the metallurgical lab for 4 months (deputed to SFL SEZ plant) and the role was to ensure incoming material (different grade steel) inspection, process development/inspection and final inspection.
• Assist in the transition of products from Research and Development to Manufacturing.
KEY PROJECTS – 1 (Cold Extrusion)
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Establish Normalising cycle, Induction hardening cycle, Quality Control and Process Control for;
o Turbine Shaft (General Motors, USA)
Erection and commissioning of Heat treatment equipments
o Sealed quenched furnace (SQF)
o Endo Gas generator
o Preheating furnace
o Washing machine
o Tempering furnace
Establish Carburizing cycle, Quality Control and Process Control for;
o Heat Treatment of Tappet for Maruti Suzuki, India
o Heat treatment of stub axle & Wheel Hub for Volkswagen
o Heat treatment of shaft for Eaton Corporation, Pune
Modified existing heat treatment cycle of GM C1 shaft to increase productivity without affecting quality.
KEY PROJECTS – 2 (Powder Metallurgy)
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Vacuum Sintering of High Speed Steel (M2) Cam Ring (customer: Stanadyne)
o Through powder metallurgy route, developed the product with full density (8.13 g/cc).
Study on Copper infiltration in valve seat (Refer attachment)
o Infiltrant- Cu Powder
o Infiltrant- wrought Cu ring.
Study on Valve seat infiltration with
o Cu powder
o CuMn powder
New Product Development
o Copper commutator for starter motor (PM route)
o Cam ring (PM route)
o Planetary gear (PM route)
o Slider block
o Valve seat
Materials Development
o Fe based Pre-alloyed mixes for sinter hardening.
o Fe based admixes equivalent to Ball-Bearing (52100) steel
o Admixes equivalent to Wrought steel with similar DI
Process Development
• Sinter Hardening
Varying composition instead of cooling rates
• Sinter Brazing
Brazed two PM steels & PM, Wrought steel
• Sinter Forging
Achieved full density in lab scale bush.
• Vacuum Sintering
Achieved full density in High speed steel
• Vacuum Brazing
Brazed two PM steels
• Heat Treatment of PM parts
Carburizing
Carbonitriding
Steam Treatment
Induction Hardening
• Plasma Nitriding of Gears.
• Sputtering
• Water Atomization
• Compaction
Warm Compaction
Functionally Graded Compaction
• Deep Cryogenic Treatment
Vendor Development
Failure analysis of wrought and PM parts
• Internal customer
• At customer end.
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