HUSNAIN أحمد

Working as independent lead auditor for Entrion and conducting in-person supplier audits across North America as per NOV checklists for special processes (Welding, NDE, Heat Treatment etc.) and QMS and writing detailed audit reports.

Developing project specific quality plans and ensuring implementation of those quality plans during project execution for multi-million dollar projects for the Oil sands and Hard Rock Mining.

•Reviewing customer requirements (MR, specification & drawings) and generating ITP based on those requirements and submitting to customer for approval.

•Working closely with fabricators and suppliers, clarifying technical questions for compliance to customer specifications. Submitting requests for information (RFIs) & technical deviation requests to customers when required for material, inspection, testing, welding and NDE related issues.

•Performing review of quality document package including procedures (Hydro testing, FAT, WPS/PQR, NDE, Visual Inspection), reports (MTR, Hydro Test Report, Visual Inspection Report, Dimensional Inspection Report NDE report, As-built drawing) and qualification records (Welder qualification, Continuity log, NDE inspector certs) to ensure package is complete & meets customer requirements.

•Providing technical support to project management team to ensure completion of all required inspections as per approved ITP. Attending pre inspection meetings in conjunction with customer, third party inspection company and subcontractor.

•For outsourced work, reviewing and approving subcontractor submitted ITP and supporting documents based on scope of work. Resolving supplier ITP issues before submission of ITP to customer for approval.

•Liaising with third party inspection company, NDE providers, welding inspectors and regulatory bodies (ABSA) to ensure that all required inspections & testing are carried out as per project requirements.

•Reviewing final QC packages submitted by vendors for the spool fabrication to ensure fabrication & testing is carried out as per approved drawing, ITP and relevant construction code (ASME B31.3).

•Implementing incoming inspection plans for parts received at the central warehouse for Oil Sands & Hard Rock Mining projects, issuing supplier NCR for non-conforming parts.

•Reviewing customer complaints, analyzing the cause of non conformance, and implementing corrective action related to Oil Sands & Hard Rock Mining products.

•Supporting field engineers at service centers (Fort McMurray, Calgary & Kamloops) for pumps, cyclones & knife gate valves performance related issues to help understand the problem and recommend solutions in consultation with subject matter expert (SME) as part of the NCR process.

•Performing quality audits to ensure compliance to ISO 9001 QMS for all Weir sites across Canada. Performing QMS audits to ensure ABSA regulatory requirements are fulfilled for manufacturing and repair of Category C fittings. Supporting HSE manager in performing audits for ISO 14001 & ISO 45001.

Conducting Quality Management System audits (ISO 9001, API Q1 & API Q2) for clients on behalf of The ISO 9001 Group following the guidelines of ISO 19011.

•Performing onsite and remote / live virtual audits via “Zoom”, “Teams”, “GoToMeeting” apps including Gap Analysis & Pre-Certification audits and writing detailed audit reports.

Monitored the performance of Extrusion, Anodizing, Painting and Fabrication (doors & windows) departments through KPI on daily basis and reported to senior management.

•Reviewed customer complaints, analyzing claims, determining root cause, and implementing corrective action. Performed product & process audits to ensure compliance to documented procedures & control plans.

•Led cross functional team of experts during problem-solving activities to solve complex problems. Provided quality related trainings to new hires as well as existing employees.

•Updated process control plans, analyzed data and provided recommendation for improvement. Maintained QMS related documentation and calibration of tools/instruments.

Supervised welding, heat treatment, upsetting, threading, hydrostatic testing & visual inspection of Casing and Tubing and ensured that pipes meet the requirements of API spec 5CT & API spec 5B.

•Managed the ISO 9001 & API Q1 Quality Management Systems & ensured compliance with certification audits by continuously improving quality related procedures, reviewing ITP & addressing audit nonconformities (NCRs) using structured problem solving techniques and utilizing Management of Change (MOC) process to manage changes in system & process.

•Performed internal & supplier audits to ensure compliance as per API Q1 & ISO 9001 standards. Updated the criteria for inclusion of new supplier and evaluation of existing supplier’s performance.

•Assessed technical competency gap/training need for NDT & visual inspectors, developed training curriculum & delivered training for new hires and existing employees.

•Led risk management activities for the plant including but not limited to identifying risks, creating risk matrix, developing risk mitigation & contingency plans.

Ensured that forming, welding and testing of line pipes is carried out as per the requirements of CSA Z245.1 & API spec 5L.

•Reviewed customer inquiries, performed technical specification review (TSR) & evaluated customer requirements against mill/production capabilities. Subsequently generated manufacturing production specification (MPS), and Inspection & test plan (ITP) based on contract requirements.

•Conducted periodic product & process audits to ensure conformance with documented procedures; identified nonconformance & generated corrective and preventive actions reports (CPARs). Successfully implemented the requirements of API Q1 & ISO 9001 Quality Management Systems.

•Attended project kickoff meetings as well as pre-production meeting with customer & Third-Party Inspection (TPI) Company to document witness and hold points.

•Performed first party (internal) and second party (vendor) audits to ensure compliance with ISO 9001:2015 & API Q1 standards as per the guidelines of ISO 19011. Developed criteria for inclusion of new supplier evaluation into Approved Supplier List (ASL) and monitoring of supplier performance.

•Reviewed NDT and welding procedures in conjunction with company NDT Level III and welding engineer.

•Coordinated & managed the continual improvement process utilizing structured problem-solving techniques (RCA, A3, 5 Whys) to resolve mill issues, non-conformances & customer complaints.

•Actively participated in risk assessment studies, prepared plans for risk mitigation & contingency and managed the management of change (MOC) process.

Managed material testing lab to ensure destructive and non-destructive testing (NDT) of OCTG casing and tubing meets the requirements of API 5CT. Provided technical guidance to mill supervisors regarding material quality, non-destructive testing, welding, heat treatment and threading related issues.

•Performed periodic calibration of inspection and measuring equipment and gauges as per the requirements of API 5B and maintaining related calibration records. Reviewed and approved standard operating procedures for material testing and gauge calibration.

•Performed in-house trials for evaluation of material supplied by new suppliers. Conducted material failure investigations & wrote detailed failure analysis reports.

•Implemented the requirements of ISO 9001 & API Q1 Quality Management Systems. Periodically reviewed and approved calibration procedures, data sheets for compliance to the standard.

Performed material characterization, destructive &nondestructive testing, welding inspection and metallographic evaluation of steel pipes (tubing and casing) as per API 5CT.

•Carried out visual welding inspection, ultrasonic testing (UT), magnetic particle inspection (MPI) & metallographic evaluation of pipes for welding defects & reported weld quality to mill supervisor. Calibrated inspection & measuring equipment & maintained related records.

Independently managed day-to-day activities of an advanced material testing laboratory of aerospace sector having facilities for material characterization, micro structural & coating analysis, corrosion testing, failure investigation, destructive and non-destructive testing of metals & alloys.

•Led the QMS activities of the department including development of quality system procedures, review & approval of quality test plans, establishment & monitoring of KPI for quality improvement.

•Provided technical support & training to production departments regarding material selection, heat treatment, machining, NDT and welding.
•Worked as project manager & established metallographic analysis and NDT laboratories.

•Performed internal and vendor audits to ensure compliance to AS 9100 and ISO 9001 standards.

•Maintained overall compliance to AS 9100 & ISO 9001 standards including but not limited to evaluation and disposition of Non-Conformances (NCRs) related to materials and processes.

•Resolved customer NCRs by performing root cause analysis, and implementing corrective actions.

•Conducted metallography, fractography & failure analysis of aircraft components & prepared failure investigation reports for fatigue, wear & high temperature degradation mechanisms.

•Developed curriculum for departmental promotion examination (DPE) in the field of “Metallurgy & Materials Science” and published a book entitled “Metallurgy”.

Supervised metallurgical testing laboratory of defense sector having facilities for material characterization, destructive and non-destructive testing, heat treatment, metallographic evaluation, corrosion testing, coating evaluation and failure investigation of wide range of products.

•Assisted in implementation of the requirements of ISO 9001, ISO 14001 & ISO 17025 standards & ensured compliance with certification audits by continuously improving quality related procedures & addressing audit nonconformities (NCRs).

•Conducted vendor & sub-contractor audits for inclusion in approved vendor list. Resolved day-to-day quality related issues on shop floor as well as addressed customer complaints by performing root cause analysis and implementing corrective actions.

•Actively participated in material selection and research & development activities in collaboration with allied departments regarding heat treatment, welding, castings, forgings, extrusion & rolling.

Worked in metallurgical laboratory of Research and Development sector and performed material characterization, microstructural evaluation, mechanical testing, heat treatment, NDT and analytical testing of wide range of materials.