• Gender: Male
• Age: 37
• Designation: Production Engineer / Manager
• Highest Education Level: Post Graduate Diploma
• Notice Period: 30  Days
• Work Experience: 13.4 Year(s)

Education

Post Graduate Diploma In Plastics Processing And Testing Bhubaneswar, Odisha in 2011

Bachelor of Science in Chemistry From Berhampur University, Odisha in 2009

Skill Sets

100% QA & HSE Documentation in place.
Consistency in Product and Process quality.
Reduction of Customer Complaints
Successful completion of audit, No critical NCRs during customer & certification audits.
Timely technical /quality support to internal and external customers.
HSE Compliance.
Efficient risk evaluation of new materials quality
Optimizing costs in product formulation
Compliance to QMS audits (ISO 9001, BIS, DIN, SASO, NSF, ARAMCO Etc) and re-certifications

Windows 7 & Windows 10, Microsoft Office, ERP, SAP, FOCUS & Ax-dynamics.

Work Experience

Quality Control Engineer/Manager -Plastics Plant
From - Apr 2018 to till date
Company Profile: Manufacturer of superior quality pipes.

Job Profile:
This position is responsible for creating and maintaining a Quality system which is capable
Of delivering to customer expectations as well as meeting all internal customer Requirements
Ensure quality of output through appropriate intervention, inspection, and testing to pre-determined quality parameters in respect of
Raw material, Packaging material, In process materials & Finished goods.
Respond to customers complaints and implement corrective and preventive action
Work to resolve inter-intra departmental quality issues
Develops and implements effective programs, processes, and methods to ensure compliance with regulatory requirements and industry standards.
Manages all quality processes associated with customers need.
Visiting customer for assurance and/or resolution of issues due to complaints & product related clarifications
Maintaining and improving product quality by completing product, company, system, compliance and surveillance audits from certification bodies for QMS
Developing new products, Cost optimization and Product and Performance improvement
Monitoring vendor performances and establishing criteria and rating systems
Monitoring the accuracy of ERP recipe and formulas
Understand, reflect & practice organization’s vision & values.
Prepared check list, SOP, daily report for online inspection as well as for lab testing instruments.
Hands on experience for coordination for third party vendors about purchase lab instruments.
Provides training for new joining employees & QC technicians.

Quality Supervisor-Plastics Compound Plant
Jul 2017 to Dec 2018
Job Profile :
Raw materials processed in compound plants commodity plastics and engineering plastics like LLDPE, HDPE, PC, PS, ABS, PA6 (Nylon6), PA66 (nylon 6, 6) etc. Having different grades Glass filled and unfilled And so on.
Ensuring adherence to quality standards and maintaining all related documents; identifying areas of quality failures and implementing system wide preventive & corrective actions in order to avoid the re-occurrences.
Taking stringent quality measures including preparation / maintenance of necessary documents and conducting audits to ensure compliance with standards.
Developing methods & validating analytical systems i.e. testing of methods to ensure that they are precise, accurate, reproducible, "fool-proof" & specific to product.
Reviewing the SOP’s / technical specifications validation protocols, validation reports and other quality documents / change-control procedures for SOP’s.
Managing the operational performance of the Incoming Quality Department, ensuring the delivery of Key Performance Indicators (KPIs) and objectives
Engaged in:
Control calibration, verification and monitoring (by using internal & external support) of all testers & process measurement devices.
Maintaining CAPA for in-house & conducting detail analysis of customer complaints related to functional problem of products.
Executed the Prime Polyolefin compounding and master batches by addition of extra ingredients such as antioxidant, talc, stabilizers, colors and other additives during extrusion process on high productivity Coperion Extruders & steer extruders having K-Tron Feeders and Nordson (BKG) Unwater Pelletizing System.
Administered the compounding tolling business and provided service to external partners.

Quality Inspector-Quality Control
Aug 2014 to Mar 2017
Company Name : Petrochemical Conversion Company Ltd.
Job Profile :
Set up a lab with commission of lab equipment, prepare documentation according standards.
Hands on experience for Purchase necessary standards and lab instruments for testing.
Prepare daily quality reports, weekly QC reports; monthly analysis reports quarterly analysis reports and yearly analysis reports.
Maintain monthly internal calibrations, monthly quality objectives report.
Review quality procedures with QC team.
Training of new hired employees and operators about quality plan, policy and objectives.
Follows up quality plan for incoming raw materials, in process raw materials and finished products inspection.
Maintains quality documents as per as ISO-9001-2015, ISO-9261, AS 2698.1:1984, ISO-8796, ISO-11922-1, ISO-1133, ISO-527-1, ISO-18553, DIN-8072-8073/74, ISO-4427 AND ISO-4427.
Co-ordinate and prepare all records and documents for external and internal audits. Like SASO AUDIT, ARAMCO AUDIT, NSF AUDIT, ISO-9001-2008, FM & BSI.
Conduct routine tests like, MFI test-ISO-1133, tensile test-ISO-6259, density test-ISO-1183, Heat reversion test-ISO-8796, color dispersion test, carbon lack dispersion test-ISO-18553,ESCR test, hydro static pressure test, Flow rate test, Burst test. ISO-1599, Oxidation induction test.
Raw materials handle: PP, HDPE, and LDPE, PE100, LLDPE, MDPE.
Material suppliers: BOROUGE, TASNEE, SABIC, HALDIA Petrochemicals, Saudi Polymers.

Achievements
Received the Employee of the Month Award in Jul’15 for outstanding performance & contribution in safety and quality.

QA Associate Executive
Dec 2011 to Jul 2014
Company Name : Essel Propack Ltd
Job Profile :
Having knowledge of Raw material testing, GMP & HMP and SAP. & maintains documents by ISO-9001-2015.
Online inspection as per as sampling plan & Shade card approval.

Production Shift In-Charge
Nov 2010 to Dec 2011
Company Name : Supreme Industries Ltd.
Job Profile :
Production planning, reporting, Capacity utilization, Product costing, Responsible for day to day production Foam Extruder, XLPE, KNEADER, Two Roll Mill, & Press and technical activities related to shop floor. Manpower utilization, Productivity improvement, Hands of exp. in LDPE & P.P Extrusion
Extrusion Operation and troubleshooting. Scrap control and housekeeping.
Behavioral based safety {B.B.S} points monitoring.
New product development process – Execution of new product trials as per plan.
Ensure effective execution of instruments calibration.
Safety, Health & Environment mgt. processes: Plan, Manage, monitor & improve the following processes.
Safety review process – Implementation of Safety committee .
Accident / Incident reporting & investigation process – all incidents including near miss cases.
Safety audit & closer process- Implementation of actions against safety audit findings.
Implementation of actions against non-compliance.
Others processes like – Manage, monitor & improve the following processes.
Rejection controls by using Sampling plan.

Safety Awareness Training's Attended / Offered
PPE Usage in Plant, JSA (Job Safety Analysis) Ergonomics, Emergency Response, Fire Drills, Blood Borne Pathogens, Hearing Conversations, Work Permit, General and Special Work Permit, LTT, Lifesaving Rules(LSR), Tenets of Operations, Safety Harness Training, Work at Heights, Scrap Folding, MOC, Forklift Training (16 ton).
Scissor Lift Training, Boom Lift Training, Waste Disposal, Fire Extinguisher Training, Eye Wash Shower, GMP & so on.
Implements & Maintains Waste Inventories and Process Advice On All Waste Disposal And Recycling Matter.
Preparation and Execution of Emergency Exercise and Response.
Environmental Awareness, Safety, Controls and Waste Management Exercises.

Certifications
Six Sigma-Green Belt & 5s training from Petrochemical Conversion Company Ltd. Saudi Arabia.
Presentation Skills from Training & Management, Petrochemical Conversion Company Ltd. Saudi Arabia.
Certified for Dynamics AX for New Users, SANDS-Safety Awareness Needs Daily Spotlight, EDMS-Electronic Document Management, and Computer and Communications Systems Policy & Cyber Security Awareness.
ISO 9001:2015 Awareness and Six Sigma Green Belt from IACT Global, India.
Blown film machine, injection molding machine, hdt & v-cat machine, Melt flow index machine, elongation machine etc.…all these machines operating training gained from machine suppliers & certificate achieved.

Machinery Operating Knowledge:-
Omega ferromatic 200 t- 300 tons, Hai-Tai 250 tons, Engel 300tons, Akar 120, Arburg 150-350 tonnage, sumo180. Asian, batten field, desma 180T, 250T, arburg-165ton-300ton.
Coperion & Berstorff twin screw die face cutting & water medium extruder, Steer twin screw extruder, XLPE foam, PU foam extruder, HDPE & Upvc pipe extruder (Cincinnati), Milacron, smi, asb international, Drip irrigation pipe extruder (maillfer), and Lamination and Capcell plant.

Chemical Handling Knowledge:-
Karl Fischer reagent, glucagon solution, Iso–propanol solution, methanol solution.

Polymer Testing Devices:
Melt flow indexer (Gottfert)
Colorimeter (Hunter lab)
Moisture analyzer (Computrac and Precia molen)
Optical control system (OCS)
FTIR (Perkin-Elmer)
Tensile and Flexural tester (Zwick)
Impact tester (Zwick)
HDT & Vicat (Instron)
Blow film machine (Techno canto)
Mooney profile check (Gibitre)
Injection moulding machine (Engle)
Muffle Furnace (Nabertherm)
Sieves shaker (Filtra/Endicott)
H & V Flammability tester
Glow wire tester
Oxygen induction time (OIT)
Specific gravity test
Heat Reversion Test-ISO-8796
Colour Dispersion Test, ESCR Test
Carbon Black Dispersion Test
Hydro Static Pressure Test
Flow Rate Test, Burst Test
Oxidation Induction Test & Band Beck Test
BFC / Torque/ Top Load / Leak / Drop Test

Core Competencies:
Quality Assurance & Engineering
Audits (Internal / External) & Compliance
Cost Saving Initiatives
Vendor Development
System Implementation
Laboratory Setup
Quality Control Device Management
Training & Development
Statistical Studies
Purchase lab equipment’s from different nations & deal with suppliers.
Area of Expertise: Quality testing (Polymer and analytical) devices:

Profile Summary
High-energy professional with rich experience of over 09 years; managed quality operations in Polymer Plastics Compounding, HDPE Pipe, UPVC pipes & fittings, HDPE & LLDPE water tanks, FRP & GRP products, UPVC doors, Drip Irrigation, HDPE Bottles & PET Preform & Bottles, XLPE Foam, Capcell, Laminated Tubing, Printing, Recycling and Rubber industries.
I have set up experiences for new plants of quality control lab like blow moulding, PET bottle & preform plant, extrusion molding, injection molding plant, HDPE & UPVC pipes & fittings plant, UPVC door plant, LLDPE water tank plant, HDPE water tank plant, FRP plant, GRP plant, compound plant (commodity & engineering plastics), rubber plant & recycling plant.
Skilled in conducting process audits & product quality audits, identifying areas of improvements & taking steps to correct & prevent further occurrence of repeated issues.
Coordinated with departments, process developments & technical evaluations to achieve operational excellence at the lowest overall cost
?Contributed as the team member for process improvement project & reduced cost by applying Six Sigma concepts (DMAIC)
Steered efforts towards:
?Designing / establishing laboratory from 0 hour to milestones production level
Introducing 5’s techniques throughout the department
Ensured compliance to quality measures as per ISO 9001:2015(QMS), ISO 14001-2015(EMS), OHSAS(45001-2018), ISO 22000:2005, German Din Standard, ASTM Standards, BSI, BIS, ANSI, SASO, NSF, WRAS, AWWA, FM Approval, ISO 4427, BS3505-06, BS4660, BS4514, BS6099 for conduit pipes, BS5255, DIN8061-62 & ASTM-D1785 and company safety norms.
?Acquires a clear understanding of technology & trends with merit of instituting new metrics / measurements for different functions in process operations; an effective leader with capabilities in training teams for running successful processes

Future Goals

A result-oriented professional with excellence in implementing quality mechanisms to deliver desired output, targeting managerial assignments in production & Quality Assurance & Control with an organization of high repute, preferably in polymer industries.