Request Expert

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.