GDC Engineer, Sr. Engineer - Alloy wheel plant (Aluminum)

Knowledge about Standard Operating Procedure (SOP) on these machines:

• Chip melting
• Tower melting furnaces
• GDC machines
• Riser cutting machine
• Deburring machine
• Heat treatment(T6) for alloy wheels
• Sizing machine
• Shot blasting machine
• ABB Robot programming change and path setting
• Core shooter machine

Key Result Area

• Planning & controlling the production operations as per the capacity available and sales projection
• Preparing & executing production operations in the coordination with the other functions
• Managing the workmen for achieving the periodic production targets
• Following standard operating procedures, manuals and work instructions for production operations for the unit
• Accountable for machine full auto running and trouble shooting
• Knowledge of GDC machine operations (wangfie and poonam tech)
• To Handle and Knowledge about T-6 type heat treatment process for two wheeler and shot blasting.
• Knowledge about alloy metal treatment and alloy making.
• To maintain constant density of metal and temperature of the metal.
• Handle the re-melting process with(03%to04%metal loss)
• Knowledge about die assembling and disassembling
• To do make proper die maintenance.
• Some modification done means change the air vent profile for reducing non filling percentage.

KEY SKILLS

• Cooling parameter setting on all model HERO and TVS wheels
• Cycle time reduction in Hero and Tvs castings(210sec to 180 sec)
• I am certify by ABB robot team for making path setting in program and change The path velocity to GDC pouring robot and 6 axis synchronizing system
• Resolve maintenance related problem in GDC and RCM
• Making programming and profile setting for auto Deburring machine

Achievements

• Ferrous (fe) control in chip melting process (0.31% to 0.23%)
• Reduce melting loss in chip melting process (6% to 4%)
• Gas saving project through preheating of air and gas mixture(10 kg per day on each furnace)
• Lead the QCC team of project to reduce Blowhole and Non filling and achieved targets with defined.
• Top cavity insert design changed for reducing shrinkage on hub area in front models
• Reduce cycle time in HERO and TVS wheels(210sec to 180) (15 per hr)
• Riser cutting machine changing operations from Hero to Tvs setting time period reduce from 60 min to 30 min.
• Improve production rate in Single Rotor Riser cutting manual machine(rcm) before 30nos per hour after modification 40nos per hour.
• 4 Rotor automatic riser cutting machine (wangfie) cutting tool life time increase.
• Heat treatment cycle time reduction before 12hrs after change 11hrs approval taken from Hero and Tvs customers
• Heat treatment Basket design change due to eliminate sizing issues and control run out in wheel

• Foundry Machine Layout
• Installing and commissioning GDC cell for TVS Customer with automation
• Production part approval process (PPAP) documentation.
• Machine inspection and added some valuable operation for improving production rate and for machine run in auto condition.
• Making knowledge of melting tools like scrapper , skimmer and launder for metal transfer
• GDC casting tools like ci pusher and wire mesh maker
• Heat treatment basket designing and making
• Making of sizing hammers