Corporate General Manager Foundry Plant Operations & Quality
Mantri Metallics Pvt Ltd Shiroli MIDC Kolhapur Maharashtra India
Total years of experience :34 years, 10 Months
Rejection analysis, Reduce rejections cost in process Implementations of Lean management . Six Sigma Reduce Customer complaints
Versatile, accomplished and competent professional with dynamic career of over 27 years in Foundry & Metallurgical Operations inclusive of Production, Process Enhancement, Internal Control, New Product Development and Quality Assurance / Control
Expertise in developing & streamlining systems with proven capability to enhance operational effectiveness and meet operational goals within the cost, time & quality parameters
Skilled in monitoring the complete operations entailing planning, resource utilization, maintenance, quality management & manpower management
A strategic planner with expertise in implementing cost saving measures to achieve reduction in terms of production & process cost
Specialist in commissioning the new projects right from layout projection to final production
Detailed experience in foundry shop and metallurgy of Cast Iron, S.G. Iron Steel Melting, D5S, Turbine Housing & Bearing Housing Castings with Shell Molding
Specialist in development of Cylinder Head, Cylinder block, Radiators, Disel Engines, Compressors, Pumps Chilled Cast Iron Valve Tappets, Spacer Rings, High Chrome Rings & Camshafts, Pump, Valve, Turbine Housing, Brg Hsg, Exhaust Manifold, Planatory Carrier, Wheel Hub horizontal and centrifugal castings Liners, Valseat insert’s rings and many more
Credited for TPM implementation, Lean projects for cost reduction, VSM, SMED, 5S+1, Kaizen for 4 plants in all areas, Six Sigma Green Belt Projects, and more
Proficient in the areas of designing chemical and metallurgical parameters for achieving sound castings with desired mechanical and metallurgical quality
Efficient organizer, motivator, team player and a decisive leader with the capability to motivate teams to excel and win
Handling Customer complaints of : Sundaram Fastners, Bajaj Auto, Turbo Energy, Haldex, Dayco, Godrej, Poclain, Honeywell, Tata Motors, Dana, Daimler, Navistar, Chassis Brakes, Cummins Indore, Hyundai,
Manufacturing brake parts S.G. and grey iron castings,
1. Reduction of internal and external rejections
2. New part development with feasibility report and PPAP approval
3. S.G. Iron Melting, No bake molding, High pressure molding, flask less molding
4. Quality Management Systems, Reduction of cost through detail analysis in process variations as cost in process
5. Implementations of Vapco Projects
6. Implementations of Kaizens and 5S
7. Rejection control through scatter diagram & metallurgical analysis
8. Improvements through Internal Quality audits and 1S, 2S audits
9. Reduction of Customer complaints
Manufacture of Automobile parts for Tata Motors, Dlw Liners, Valve seat inserts High chrome valve seat inserts, Tappet, Spacer rings.
1. Rejection analysis & reduction of cost in production Process
2. Rejection analysis and their rectifications
3. Total support to marketing interactions with customers
4. Internal Quality Auditor Training ISO 9001:2008 TUV NORD
5. New product development / Interpretation of drawing / Feasibility study
6. CAPA for root cause analysis for rejections, casting defects, Customer complaints
7. Knowledge of chemical and physical properties and metallographic
8. Renumeration of Nobake Foundry
9 Horizontal and vertical centrifugal liner production Sinto flask less horizontal high pressure molding, S.g. iron melting, Tappet, Spacer ring valve seat inserts, High chrome melting , Process control . Implementations of kaizens
Manufacturer of Chilled cast iron Camshafts, 100 % Export oriented Unit. Metallurgical and chemistry control, shell core manufacturing, Reducing the crack rejections through detail study of solidification of castings., reduction of cold defects through detail rejection analysis through scatter diagram, controlling ppm level at Customer end . QMS and Lab process modified and streamlined.
Manufactures of Pump Casings, Valves, Impellers .
High pressure molding, continuous process molding with 6 ton capacity cast iron melting., Conversion of Oil sand cores and heavy molds of pump casting to no bake with development of 21 vendors from 3 vendors .Reduction of 38 no’s workers strength from core shop and hand, molding and transfer to machine shop .
Physical Metallurgy , Foundry Technology , Material Science , Extractive Metallurgy , Powder Metallurgy , Extrusion , Chemical and physical testing , Photomicrography .
Study of Physical Metallurgy , Foundry Technology , Extractive Metallurgy , Heat Treatment , Melting of S.G. Iron , Cast iron , Vermicular cast iron , steel , High chrome melting for Centrifugal vertical and horizontal molding , Green sand molding flaskeless molding nobake molding