Expert Details

Expert in Steel Foundry Method Pattern Development Technology and Production of Sand Castng

Expert ID: 729770 India

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Expert has 21+ years of experience in steel foundry method pattern development technology & production personnel. He has done much foundry work in different countries. He has worked in heavy, medium & small casting foundries; indicated in responsibilities column of work history with weight range in each foundry ahead. He worked with steel, cast iron, alloy steel, alloy cast iron, Mn-Steel, S.G. Iron and Non-ferrous casting (i.e. brass, bronze & aluminium). He has worked for single piece casting of 21 MT to few kilograms. He has worked with hand moulding, machine moulding & semi automatic moulding. He has worked with green sand, CO2, PHENOLIC & FURAN SHELL sand system & centrifugal casting system. He has worked with PIT MOULDING & MOULDING BOX for development & production. He has worked with foundries having ELECTRIC ARC FURNACE & INDUCTION FURNACE. Also the furnaces were BASIC EAF and INDUCTION FURNACE of two types ie, monotrack & dualtrack.

Covered Responsibilities:
a) Sample casting development: Development of all new jobs in the organisation through following stages:
i) Technical review of customer drawings & specifications.
ii) Preparation of detailed technology.
iii) Developing patterns through approved vendors.
iv) Giving technical assistance to moulding dept.during sample casting production.
v) Analysis of sample casting results. Taking corrective & preventive action to overcome the shortcomings.
b) Production Planning & Control activities.
c) To train the local personnel in understanding the pattern - making drawing and guide them to make the patterns.
d) Corrective & preventive action of the items and attend the customer complaints.
e) Involved in development of new fast loop moulding plant & semi automatic moulding plant till erection and commissioning.
f) Improvement in the regular production items.
vi) Customer liaison. Liaison activities include Customer and Sub-contractor visits where necessary. General Customer liaison on any other quality related issues, e.g. e-mail correspondence, etc.
vii) Maintenance and development of the QMS to maintain ISO 9000 accreditation. This would encompass all aspects of system management along with the ability to be part of the audit team.
viii) To manage all incoming Customer complaints through to closure utilising the prescribed Customer response method, e.g. 8D, Customer 'on-line' reporting systems etc.

Other activities:
i) Manufacturing cost estimation. To study the technical specification of the castings from the received purchase order (PO) & compare with that of the enquiry stage. Get clarified the doubt of requirement if any from the customer through marketing. dept. Also to visit the customer for technical clarification. Active participation in the contract review on receipt of the techno-commercially clear PO. To raise the technical query / suggest alternative modification to fulfill the contract. Also to visit the customer to educate / to discuss technical clarification. Also to prepare technical feasible production report.
ii) Active participation in ISO-9000 Quality System.
iii) Economise the pattern making.
iv) Establish the economical detailed manufacturing technology.
v) Involved in the development of the “ADAMITE ROLL”Castings for Rail & Universal Beam Mill.
vi) Involved in the development of the tube/pipe castings of HK40 grade in Centrifugal casting system, for various Sponge Iron units.
vii) Involved in the development.of Mn-Steel castings for Mining & Ore Processing, Cement Plant, Excavation Parts,Stone Quarries, Steel Plant etc.
viii) Development of heavy S.G. Iron castings.
ix) Development of Casnub Bogie castings for Rly., including technology, tools & tackles and Q.A. & recording Systems.

Education

Year Degree Subject Institution
Year: 1989 Degree: BE Subject: Mechanical Engineering. Institution: Govt. Engg. College, Raipur (C.G.) INDIA.
Year: 1984 Degree: DME Subject: Mechanivcal Engg. Institution: Govt. Polytechnic, Durg (C.G.) INDIA.
Year: 1982 Degree: Higher Secondary School Certificate Exam. Subject: Physics, Chemistry, Maths. Institution: Govt. Multipurpose Higher Secondary School, Bilaspur (C.G.) INDIA.

Work History

Years Employer Title Department Responsibilities
Years: 2009 to Present Employer: Undisclosed Title: Foundry Technologist Department: Responsibilities: Working as foundry technologist.

Years: 2008 to 2009 Employer: M/s. Prayas Engg. Ltd; (ELECONGROUP).Anand (Gujarat) India. Title: Sr. Manager (Production). Department: Foundry Responsibilities:
Years: 2007 to 2008 Employer: M/s. Steelcast Ltd.; Bhavnagar (Gujarat) India. Title: Manager (Production) Department: Engineering Responsibilities:
Years: 2005 to 2006 Employer: M/s. Tema Steel Co. Ltd.; Tema (Ghana). Title: Specialist. Department: Foundry Responsibilities:
Years: 2004 to 2005 Employer: M/s. Jindal Steel & Power Ltd.; Mandir Hasaud, Raipur (C.G.) India Title: Deputy Manager Department: Foundry Responsibilities:
Years: 2004 to 2004 Employer: M/s. Nigerian Foundry Ltd., (Components Foundries Ltd.); Lagos (Nigeria). Title: Managerial Capacity in Production Department Department: Foundry Responsibilities:
Years: 1999 to 2003 Employer: M/s Alloy Steel Castings Limited.; Nairobi (Kenya). Title: HOD Method & Pattern Shop Department: Foundry Responsibilities:
Years: 1990 to 1999 Employer: M/s Simplex Castings Ltd.(special Casting Division); Raipur (C.G.) India. Title: Deputy Manager Department: Foundry Responsibilities:

International Experience

Years Country / Region Summary
Years: 1990 to 2003 Country / Region: Nairobi (Kenya). Summary: Start Date: March ’99 End Date: Jan’03.

Description :
It is jobbing foundry located in African Continent at Nairobi - Country Kenya with ISO.9000-2000 certification for its quality system. It manufactures Steel, Cast iron, Alloy Steel, Alloy cast iron, Mn-Steel, S.G. Iron and Non-ferrous casting i.e. brass, bronze & aluminium: for general engineering industries. 70% of its products are being exported to U.S.A, Germany, Netherlands, Uganda, Tanzania & other countries. Alloy steel is equipped with fast loop moulding line (flask less).Also equipped with 1MT two crucible Induction Furnace. Product Range Steel & alloy Steel : 1 Kg to 1500 Kgs Cast Iron & Alloy cast Iron : 1 Kg to 2700 Kgs S.G Iron : 1 Kg to 1500 Kgs Non Ferrous : 1 Kg to 800 Kgs Production Capacity : 150 MT/Month Responsibilities a) Sample casting development till establishment through various deptt. of process. b) Production Planning & control Activities. c) To train the local personnel in understanding the pattern - making drawing and guide them to make the patterns. Other activities i) Assist in cost estimation for manufacturing the casting. To check the customer’s enquiry for csgs. production during contract review. To raise the technical qurrey / suggest alternative modification to fulfill the contract. Also to visit the customer to educate / to discuss technical clarification. ii) Economise the pattern making. iii) Establish the economical detailed manufacturing technology. Achievements during services a) Development of various casting for U.S.A, Europe market first time around 100 patterns. b) Development of the various castings for Cement, Sugar, Automobile, Stone Quarries, breweries etc.

Years: 2004 to 2004 Country / Region: Lagos (Nigeria). Summary: Start Date: May’04, End Date: Oct’04.

Description:
It is jobbing foundry located in Western African at Lagos - Country Nigeria with ISO.9000-2000 certification for its quality system. It manufactures Steel, Cast iron, Alloy Steel, Alloy cast iron, Mn-Steel,: for general engineering industries. 80% of its products are being exported to Ghana, Togo, Benin Republic, Niger, Cango & other countries. Also equipped with 1MT & 500KG. each two crucible Induction Furnace. Product Range Steel & alloy Steel : 1 Kg to 1000 Kgs Cast Iron & Alloy cast Iron : 1 Kg to 1000 Kgs Production Capacity : 200 MT/Month Responsibilities a) Sample casting development till establishment through various deptt. of process. b) Production Planning & control Activities. c) To train the local personnel in understanding the pattern - making drawing and guide them to make the patterns. Other activities i) Assist in cost estimation for manufacturing the casting. To check the csgs. production feasibility. ii) Economise the pattern making. iii) Establish the economical detailed manufacturing technology. Achievements during services a) Development of the various castings for Cement Plant, Mining & Ore Processing Excavation Parts, Sugar Factory, Telecom, Automobile, Stone Quarries, Breweries etc.
Years: 2005 to 2006 Country / Region: Tema, (Ghana). Summary: Start Date: Aug’05., End Date: July’06.

Description :
It is jobbing foundry located in Western African at Tema - Country Ghana. It manufactures Steel, Cast iron, Alloy Steel, Alloy cast iron, Mn-Steel,: for general engineering industries. 80% of its products are being exported to Togo, Benin Republic, Niger, Cango & other countries. It is equipped with hand & machine moulding. Also equipped with 1MT & 500KG. each Mono Track and 1MT Double Track Induction Furnace. Product Range Steel & alloy Steel : 1 Kg to 2000 Kgs Cast Iron & Alloy cast Iron : 1 Kg to 2000 Kgs Production Capacity : 400 MT/Month Responsibilities a) Sample casting development till establishment through various deptt. of process. b) Production Planning & control Activities. c) To train the local personnel in understanding the pattern - making drawing and guide them to make the patterns. Other activities i) Assist in cost estimation for manufacturing the casting. To review the contract & tender for supply of the grinding media to various goldfields. Also to visit the customer to educate them for csg. use. ii) Economise the pattern making. iii) Establish the economical detailed manufacturing technology. Achievements during services Development of the various castings for Cement Plant, Mining & Ore Processing Excavation Parts, Telecom, Automobile, Stone Quarries, Breweries, Rolling Mill etc.

Additional Experience

Training / Seminars
Professional Training: 6 Days Training Programme On “PATTERN-MAKING” Organised by Arkey Conference Service Cell, Pune.
In Plant Training: 35 days Service Certificate Training in BHILAI STEEL PLANT.
Other Relevant Experience
Computer knowledge:Package : A F Solidification Software, MSOffice.
Professional Project:Certificate awarded to participate in “PHOENIX PROJECT” by East African Foundary Works (K) Ltd. & Alloy Steel Castings Ltd., Nairobi (Kenya).
Self Development Programme: (1) Basic course of “ART OF LIVING” by Shri Shri Ravishankarji at Raipur during 2003-04.
(2) One day workshop on“Responsible leadership and outstanding teams for transformation & excellence” by Guruji Shri G. Narayana; the well known management expert at M/s.Prayas Engg. Ltd. Anand (Gujarat) on 04-07-2008.
(3) Four day “DYNAMIC YOGA” course & one day “Mind Power” seminar by Dr. Sneh Desai from 22 to 26-11-2010 at Chandrapur (M.S.).

Language Skills

Language Proficiency
ENGLISH Proficiency: Excellent
HINDI Proficiency: Excellent
GUJARATI Proficiency: Excellent

Fields of Expertise

coating facility, foundry operation, foundry system, foundry tech, steel casting, steel casting defect, steel mechanical property testing, steel product quality assurance, steel recycling, aluminum castings, arc melting, austenite, casting process, casting technology, continuous solid handling machine, coordinate measuring machine, electric steel melting, ferrous metal casting, ferrous metal melting, incoming steel inspection, iron casting, iron heat treatment, pipe casting, sand casting, sand reclamation, steel annealing, steel failure analysis, steel heat treatment, direct chill-casting, dry sand casting, ductile iron melting, ferrous metal machining, green-sand casting, hydrogen-induced steel cracking, steel machining, steel marketing, steel melting, steel nonmetallic inclusion, steel processing, steel product manufacturing, steel quenching, steel refining, vacuum melting, carbon steel forging, foundry machine, facsimile machine, iron foundry, steel composition, silica sand, triple vacuum-melted steel, clean steel, master alloy, scrap iron, scrap iron recycling, foundry binder resin, steel industry, plain-carbon steel, steel finishing material, steel failure, steel foundry, steel mechanical property, steel property, foundry, austenitic steel, electric machine, green molding sand, foundry sand, steel refinery, drill, alloy steel, high-speed steel, chromium-molybdenum steel, electric-arc furnace, steel product specification, steel manufacturing, steel development, ferrous metal, steel product, computer numerically controlled machine, sand-cast, iron casting (artifact), metal casting (artifact), green sand, vacuum casting, metal casting, escalator, tool steel, machine, engine, steel, steel structure, steel corrosion, stainless steel, heat-resistant steel, compressor (machine), carbon steel, austenitic stainless steel

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