Ref. No. : CA - 13548 - (Production - Moulding – with 29.8 years in Plastic Industry)

Education

Diploma in Plastic Mould Technology from Central Institute of Plastic Engineering & Technology, Ahmedabad with 1st class in August 1995

Skill Sets

Injection moulded products for Engineering, Automobile, PVC, PPR & HDPE Pipe fittings, Material handling crates & Pallets, Furniture & Cupboard products
Extrusion Blow moulded containers for Pharma & Cosmetics Packaging, lube oil, edible oil, Pesticides
Tool bags for power tools, Ice box outer body, Railway chute pipe etc
Toolroom activities for Mould Development & Maintenance
Mechanical & Hydraulic maintenance, PLC trouble shooting
3 layer flexi PE tubes with insert moulded threaded neck for packaging industries
ISO documentation, Certified ISO internal Auditor.

Work Experience

Production Incharge
Since August 2011
Company Profile: Manufacturer of injection molding products

Manager - Production & Development
Dec. 2010 - Aug. 2011
Company Profile: Leading manufacturer of injection moulded plastic goods for Luggage, furniture, toy, Electronics, Automotive, white goods, packaging, and various other applications.

Manager Production & Maintenance
Feb. 2005 - Nov. 2010
Prince Containers Pvt. Ltd.

Sr. Engineer Production & Maintenance
Jan. 1999 to Dec. 2004
Amiantit Oman LLC

Jr. Engineer Production
Aug. 1995 to Dec. 1998
Prince Multiplast Pvt. Ltd.

Enhance productivity for Plastic Injection moulding process by following improvements:
Hot runner stack moulds for Lid, tray, cap, cloth hanger type products to increase productivity, HRS spacer gape window to monitor material leakage
End-plug less Two plate hot runner manifold to minimise colour change wastage, easy to clean & burn mark prevention.
Hydraulic press machine to check mould parality & spotting for parting line fleshes.
Change gate size, position & frequency to avoid flow marks
Mould mounted cooling manifold, Pneumatic torque ranch, auto mould clamping to minimise mould change downtime.
Fix Vane pump run by AC drive can reduce power consumption during long cooling cycles
Conversion of cold runner moulds in hot runner moulds, Mould cooling frequency optimization to reduce cooling time.
Out sourcing for PLC Up gradation of old Inj. Moulding machines with optional features of intrusion, parallel refilling, core pulling, parallel ejection during mould opening
Taper locators (Individual & common) to prevent out filling problems
Blade type conveyor belt with grooved wheels for product- runner separation, pneumatic robots with vacuum pickers for scratch proof handling of ejected products
Mould readiness as per checklist of all critical functions of mould, descaling with pressure pump, Periodic preventive maintenance of mould on m/c during production to minimise B/D maintenance
Multiple hopper feeding system with individual screw for on line raw material mixing

Injection Moulding Machines handled for Production & Maintenance:
ENGEL 100, 150, 175 tons with accumulator
L&T 60, 100, 150, 550, 650 ton machines with accumulator, shut off nozzle for parallel refilling, AC drive & AC Motor for refilling
DGP Windsor FM100, FM150, Windmicro250ton, SP450, SP600, SP800, SP2000
Woojin selex 100, 250, 450 ton with variable pump electronic control
MIR 1000 ton with toggle & Hydro mechanical clamping unit
Mafatlal Nigata NN350 ton, Polyplast 150 ton, Liguang 350 ton
RR Kunststof 150 ton with servo motor & vane type pump without flow & pressure control valve.

Plastic Injection moulds Development, Production & Maintenance:
Automotive products: Wheel outer Disc, Inner parts, Knobs, side covers, mud guard, side bumpers
Stack moulds: Multi cavity Hot runner: Folding crate, lids, cloth hangers & similar flat products
Material handling Pallet: Floor pallet, nestable pallet, 4 way entry pallets of different sizes.
Pet Preforms with multi cavity fully hot runner moulds & shutoff gates.
Engineering components of ABS, ABS+PC, PC, POM, Nylon, Glass filled materials
White goods for IFB washing machine & Symphony air coolers
Multi cavity hot runner moulds with rotating cores for Unscrewing Caps & closures, Flip top caps
Hot runner moulds with collapsible core for special application products
Material handling crates, bottle crates, stackable/nestable crates, Sericulture crates
Furniture moulds: Chairs, tables, sofa chairs, sofa, wheeler containers, cupboards
Fittings of UPVC, PPR & HDPE for High pressure applications & Drainage systems

Plastic moulded Pharma Packaging Products:
Plastic Disposable syringes 2ml-5ml-10ml, IV set components, Child Resist Caps, Pilfer proof caps, Injection & Blow containers, Flip top caps, Pill off seal caps, Measuring cups, Extruded IV tube of medical grade soft PVC etc. Drug master file documentation
Familiar with Plastic Materials: HDPE, PP, PPCP, PC, PA(POM), ABS, Nylon6, PC-ABS, Glass filled materials, HIPS, SPVC, UPCV, Carbon filled conductive materials, FPP
UV stabilizers, Anti oxidants, Anti Moisture additives, slip additives
Minimize start up rejection by optimum standardized parameters.
Soft start PID temp controllers for hot runner mould to remove moisture from heaters while start up
Conversion of semi auto moulds in fully auto moulds by modifying Ejector system & HRS
Bi metallic screw barrel for glass filled materials.
PLC trouble shooting: Digital & Analogue I/O cards, PLC, Power supply.

Enhance productivity for Plastic Blow moulding process by following improvements:
Projected Flow path grooving in die ring for uniform wall thickness at corner areas in oval shape, square & rectangle containers
Twin cavity Top & bottom blowing with single perision for low height bottles to double production
Blow pin with water cooling for rapid cooling of moulded neck area
Metallic Porosity inserts for venting on moulding surface to exit cavity air
Plastic Extrusion Blow moulding production: CMP, DGP Windsor machines.
Fuel tank for automotive applications, Air duct for car dash board AC, bottles, life buoy, Railway chute pipes, customize products, Ice box inner-outer body, waste bins, Tool bags etc.

Project Management: New machines Erection & Commissioning for factory setup:
Plastic Injection moulding machines up to 1000 ton, Blow moulding machines, Air Handling Unit, Piston type & screw type Air compressors, Over head cranes, Water chillers, Cooling towers: Finless - tray type, Hot air ovens, High speed & low speed grinders/crushers
3 layer Co-extrusion flexi PE tubing plant with down stream equipments: Vacuum tank, Caterpillar Haul off with variable speed, Rotary saw unit, Vertical Injection unit for moulding
Threaded neck of tube, 6 colour offset printing unit, UV drier oven with conveyor system
Toolroom machines: Lathe machines with DRO & NC system, Universal milling machines with DRO, Hydraulic press, surface grinders, cylindrical grinder, Planner, Radial drill m/c, 3D pantograph, Spark erosion m/c, Tool & cutter grinder m/c
Roto moulding m/c: Bi axial & Rock N roll machines, Twin mill Pulverizer, Compounding extruders with Die face cutter. Rotolining of steel pipes & fittings: ACP+LLDPE twin layer OR Nylon11, 3 layer water tanks, Ice boxes, Material handling pallets, Modular booths, Road barriers, Road cones,
Chemical storage stackable tanks of PP, Man hole chambers & Septic tanks for drainage systems
Twin screw counter rotating-vented barrel extruders for UPVC pipes & profiles: single & twin die head, vacuum tanks with internal partition, Caterpillar Haul off with 2 jaws, 4 jaws, 6 jaws options as per pipe size, Rotary cutter
75mm PPR & HDPE pipe extruder machines with down stream equipments, jockey extruder for line marking on pipe OD
HDPE corrugated pipe Extrusion lines for 3meter OD pipes
45mm twin screw co rotating vented barrel compounding & palletizing extruder machines with down stream equipments
New mould development for customize applications

Developments for Toolroom activities:
Plastic mould design with concept of changing or cleaning Hot runner system, inserts & moving parts on moulding machine to minimise downtime
Lathe machine with indexing head spindle & milling attachment to make keyway, across flat, gear teeth on shaft OD
Portable spark erosion machine to make sharp corner grooves on large size punch & cavities

Toolroom activities with following machines:
Lathe m/c with DRO, Universal Milling m/c with special purpose attachments
Universal Cylindrical grinder m/c, Surface grinder m/c,
Tool & cutter grinding m/c, Radial drilling machine,
Electric discharge machine fix & Portable type, Boring m/c: Horizontal & Vertical spindles
Pantograph m/c, shaper, slotter, Hydraulic press, Planner m/c with grinding attachment
Development of Injection & Blow moulds, dies, jigs, fixtures, tools, gauges, mandrels

Hydraulics Maintenance: Hydro motors, Fixed & variable pumps, Cylinders, Accumulators, Directional valves, Proportional valves, Intensifier, Combination of digital valves for pressure & flow control,
Check internal & external leakage of hydraulic cylinders
Oil cooling for moulding machine- Use blade type heat exchanger with water & fan cooling,
For additional oil cooling insert copper tube coil with water circulation in oil reservoir
Periodic inspection of screw, barrel & ring plunger Dia. to prevent material slippage & shot weight Variation
Oil cooling for continuous running moulds to avoid descaling downtime

Pneumatics Maintenance: Valves, Cylinders, Motors, FRL, Actuators with manual & PLC control.

Utility Maintenance: Cooling towers, Gear boxes, chillers, Oil free dry air compressors, Screw type & Piston type compressors, Air handling unit, Proper Earth plate to maintain NE-EA 3 volt.

Rotating equipments Maintenance: Centrifugal pumps, regenerative blowers, Root blowers, gear type pump, piston type pump, diaphragm type pump, Conveyor belts systems, different types of gear boxes, high speed mixers, Pulverizers, Slip ring assembly

Material handling Equipment Maintenance:
Aerial Work Platform motorized, Hydraulic /Mechanical Dock Leveler, Scissor Platform- hydraulic, Pit mounted hydraulic Scissor lift

Techno commercial activities:
Profit & loss account, Management information system, Production Planning & Control
Product costing, quotation/ tender to customers: Nilkamal Ltd., Reliance Industries Ltd., GNFC, GCMMF,
Indian Railway, Symphony Ltd., IFB Ltd., Petroleum Development Oman, Ministry of Defense Oman,
Pepsico, Vijay Sabre Fire Protections Ltd.
Selection & Procurement of machines & moulds: Price, features & BOM/configuration comparison
Optimum inventory control of spares, consumables and Raw material.
Documentation of ISO 9001:2008 system: SOP, Q.A. Plan, Process data sheet, Process Guidelines,
Process validation, New mould trials & approval, Product verification & testing, Product validation
Customer satisfaction review.
Customer complaint analysis: Root cause, Corrective action, Preventive action, Cost of complaint
Statistical data analysis, FIFO system implementation
Overall Equipment Efficiency (Yield): Machine utilization %, Production efficiency %, Rejection %
Vendor development & evaluation

Lean manufacturing: Cause effect diagram, Pareto Analysis, Just In Time process, Work Cells, Kanban tooling, standardization of techniques, 5S concept, Total Productive Maintenance, Single Minute Die Exchange, lean enterprise for suppliers & customers

Future Goals

Grow professionally with hard work, leadership & commitments

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