Metallurgist – Engineer (222036) Black Belt, BS Metallurgical Engineering / Automotive, Heavy Equipment, Tools / Foundry, Rolling Mills, Extrusion, Additive Manufacturing, Forging, Broaching, Honing, Machining, Heat Treat, and Welding operations / Will relocate
Highly skilled Metallurgical Engineer with 20+ years of proven experience performing metallurgical analysis, supporting, and leading R&D projects for new project implementation for manufacturers like Klein Tools, Stellantis, and Caterpillar. He is a Six Sigma Black Belt and has achieved 97 industry certifications. He has an impressive record of producing millions of dollars in cost savings for his employers. He is an expert in induction heat treatment process development, leveraging direct experience supporting design and manufacturing. He is highly skilled in heat treatment and additive manufacturing methods that include DMD, DED, EBAM, DMLS, EBM, SHS, SLM, and SLS. He has provided Engineering Support for Engine and Powertrain powder metal, steel forging, and steel/cast iron casting components.
He is experienced in API, ASTM, AS9100, ISO, and IATF Standards. He is skilled in managing Metrology Lab processes and equipment to ensure meeting quality and specifications. This Game Changer has a strong track record in improving part/component metallurgy to improve their life, wear and tear. He is also able to plan, direct, and control quality department functions. He is looking for new opportunities and is willing to relocate for the right opportunity. His notable experience includes:
• Developed laser heat treatment with 1.5M cost saving/green process for automotive crankshaft
• Reduced average monthly external credits from non -conforming material by 25%, through design changes and process improvements
• $10M cost savings by implementing process change and new supplier development
• $40M in warranty issues through investigation of field failure analysis
• $3M cost saving by converting powder metal part from steel sheet component
• Developed laser heat treatment with 1.5M cost saving/green process for automotive crankshaft
• Optimize heat treatment parameters and develop procedure of heat treatments including quenching, annealing, carburizing, induction hardening and neutral hardening
• Perform microstructure characterization using modern materials analytical techniques, such as SEM, EDS, XRF, XRD, OES, optical microscopy and quantitative image analysis techniques
• Provide consultation support of raw materials for new product development
• Material testing and supplier qualification including chemical analysis, hardness survey, microstructure evaluation, plating thickness measurement, mechanical and physical property testing
• Troubleshoot and repair production and laboratory equipment
• Develop and maintain laboratory work instructions, testing protocols and specifications
• Coordinate and schedule Material Lab services, working with internal clients
• Provided metallurgical engineering support to Stellantis, CTC
• Wrought steel, power train, Engine and Heat-treat support
• Worked on lightweight Powder Metal and Additive Metal technology
• Worked with several Additive manufacturing processes for prototype components such as: Binder jetting, Direct Metal Deposit (DMD), Directed Energy Deposition (DED), Electron beam additive melting (EBAM), Powder Bed Fusion such as Direct metal laser sintering (DMLS), Electron beam melting (EBM), Selective heat sintering (SHS), Selective laser melting (SLM) and Selective laser sintering (SLS). Experience working with Additive manufacturing operations or related fields
• Experience working with CAD Software Experience (ProE, Creo, SolidWorks)
• Proficiency in working with casting, forging, metal forming/process and complex mechanical assemblies
• Converted low volume transmission components from wrought steel to additive manufacturing process
• Worked with gear manufacturing processes such as forging, broaching, honing, etc.
• Hands-on experience of optical emission spectrometers, an electron discharge machine (EDM), scanning electron microscope (SE), magnetic particle inspection equipment, and various hardness testing equipment
• Eliminated fretting on fuel system carburized component by adding DLC (Diamond like coating), chromium and tungsten coating
• Managed all types of non-destructive (NDT) and destructive testing of materials, and conducted complex testing
• Resolved problems with customers and suppliers by evaluating material hardness, quenching, and machining issues
• Participated in launch teams, APQP/PPAP activities for purchased components within the supplier quality group to ensure success launch and continued delivery of quality components to Caterpillar fuel system and engine plants
• API Standards
• ASTM Standards
• AS9100
• ISO 9000 / ISO9001 / ISO14001
• IATF16949/TS16949
• Ford Q1
• Performing TS Audits
• Hands-on Quality Lab Experience
• Managing the Quality Lab
• Managing Quality Teams
• Leading Kaizen Events
• Working With Lean Teams
• Leading Six Sigma Teams
• Change Management
• Performing Kanbans
• Coordinating Lab Activities
• Calibrating Equipment
• Using CMM Equipment
• 3D Scanner
• Optical Comparator
• Hardness Testing
• Environmental Chamber
• Torque Tester
• Load Testing
• Metallurgy
• Using 3D Scanner
• Cut/Etch Weld Testing
• Mechanical Testing
• X-ray
• Hardness Testing
• Metallography
• Gas Chromatography
• Troubleshooting QC Lab Equipment
• Liquid Penetrant Testing
• Non Destructive Testing NDT
• Technical Writing
• Gage R&R
• GD&T
• ISO Auditing
• Troubleshooting Root Cause
• Implementing Corrective Actions
• Implementing Continuous improvement
• Reducing Scrap
• De-bottlenecking Processes
• PPM Reduction
• Reducing Manufacturing Cycle Time
• Improving Change Order Cycle Time
• Production Attainment Metrics
• Vendor Offsite Supplier Quality
• Supplier Validation / Qualification
• Shop Floor Process Quality
• Quality Training Experience
• Production Quality experience
• Directing Quality Techs
• Tracking Concessions / Deviations
• New production line startup
• Recommending Specification Revisions
• Reducing WIP Inventory
• Creating SOP Training
• First Article Inspection FAI
• Quality Engineering
• Tooling Quality
• Using Quality Database Systems
• Process Control Quality Experience
• Performing Internal Quality system audits
• Performing External Quality system audits
• Total Quality Management (TQM)
• Setting Up Quality Systems From Scratch
• Statistical Investigations
• Investigating Customer Complaints
• Documenting Initial Submissions
• Conducting Trial Fit / Function
• Using Control Plans
• Process Flow Diagrams
• VAVE Projects
• Pareto Charts
• Poka Yoke Assessments
• Analyzing Production Limitations
• DFMEA / PFMEA
• Statistical Process Control (SPC)
• DOE Design of Experiments
• 5S / 6S
• 8D
• Ishikawa Diagrams
• Establishing Cpk For Process
• New Process Development
• Designing Process Improvement Trials
• Packaging Validation
• Generating Process Control Charts
• Process Testing / Validation
• Using Product Reject / Defect Investigations
• Delivering Cost Reductions
• Tracking Defects Per Unit
• Sorting Suspect Parts
• NADCAP
• PPAP
• APQP
• SQL Database
• Minitab Software
• LIMS Laboratory Information Management Software
• SQC/SPC Package Software
• Tier 1, Tier 2 Mfg.
• Optimizing Manufacturing Processes
• Pipe Mfg. Operations
• Tube Mfg. Operations
• Coating / Painting Mfg. Operations
• Foundry Operations
• Hot Rolling / Cold Rolling Mills
• Extrusion Operations
• CBN Grinding Operations
• EDM Electrical Discharge Machining
• Creep Feed Grinding Operations
• Melting Operations
• Blending Operations
• Forging Operations
• Welding Operations
• Blasting Operations
• Assembly Operations
• Fabrications Operations
• Heat Treat Operations
• Packaging Assembly
• Injection Molding Operations
• Metal Finishing Operations
EDUCATION
• BS, Metallurgical Engineering, Visvesvaraya National Institute of Technology, Nagpur University, India / The institute has been consistently ranked among the best fifteen engineering colleges in India.
• Six Sigma Black Belt – PMI Project Management Institute
• Heat Treatment of Steel – ASM International
• Principles of Failure Analysis – ASM International
• Basic Powder Metallurgy Short Course – MPIF
• NDT (72 Hours) / Cerritos College
• 92 LinkedIn Certifications