BIVEK SARKAR

• Accountable for proactive quality assurance (welding and cutting) of bulk material handling equipment (apron feeders, wagon tippers), steel plant equipment (torpedo ladle cars, ladles), crushers (limestone & coal), mining equipment (surface miners), and sand plant systems.
• Leads Project Pre-order and post-order review.
• Lead the establishment, programming, and commissioning of a 10-axis CLOOS Robotic Welding Machine for continuous production line production.
• Responsible for vendor development and evaluation of welding and allied processes.
• Develop and qualify WPS, PQR, and WPQ in compliance with ASME Section IX, AS/NZS, EN ISO 15614-1, and EN ISO 9606-1.
• Materials handled: Gr 12, Gr 22, SS, IS2062, SA516Gr60/70 , IS2002, hard facing.
• Welding Processes handled: SMAW, GTAW, FCAW, GMAW & SAW.
• Responsible for weld maps, SOP, Welding Quality Manual, and Work instruction preparation and implementation.
• Planning, estimating, procuring, and controlling of welding consumables, ensuring cost optimization and uninterrupted production.
• Welder & engineer skill development and upgradation by training.
• Established new materials in the workflow and resolved complex metallurgical issues related to welding operations.
• Led the implementation of ISO 3834-2 (Comprehensive Quality Requirements) and EN 1090-2 Execution Class 4 (CE certification), successfully certified by LRQA.
• Serving as a core team member for Quality Assurance Plan (QAP) development in coordination with customers.
• Manage and control heat treatment, welding, and cutting processes.
• Handle customer for final approvals.
• Lead a workforce of 100+ welders and 6 management staff, including the development of performance metrics and evaluation systems.
• Responsible for failure analysis of weldments.
• NCR management and control
• Drive new process setup, shop development, and welder skill enhancement to increase production capacity.
• Fully accountable for product weld quality across the manufacturing.
• Digital Initiative- IoT-enabled welding machines to evaluate and improve Overall Equipment Effectiveness (OEE).
• Responsible for the CAPEX of welding equipment.
• Supervisor development related to welding coordination.

• Accountable for proactive production planning and execution of nuclear turbine manufacturing, ensuring adherence to stringent nuclear quality and regulatory requirements.
• Managed and controlled all critical manufacturing processes, including heat treatment, welding, rolling, blasting, and painting.
• Led a workforce of 60+ workmen and 3 management staff, developing and implementing a performance matrix to drive productivity and accountability.
• Drove new process setup and process development to improve manufacturing capability and efficiency.
• Spearheaded the establishment of a new production shop, resulting in increased capacity and improved throughput.
• Ensured strict compliance with nuclear quality standards, maintaining full traceability, documentation, and process control.
• Implemented Lean manufacturing practices on the shop floor to eliminate waste, improve flow, and enhance productivity.
• Enforced robust safety policies, achieving zero incidents, zero near misses, and zero Injury Frequency Rate (IFR).

• Accountable for proactive Welding and Quality of pressure vessels and critical components, including headers, piping & panels, FGD systems, and mill products.
• WPS/PQR/WPQ establishment of materials such as Gr91, Gr92, Gr22, Gr12, and SS 304, SS347 ensuring strict compliance with ASME requirements.
• Responsible for consumable estimation, procurement, and control.
• Led a team of 70+ shop-floor welders and 2 management staff, ensuring high productivity, skill development, and accountability.
• Collaborated cross-functionally with Planning, QC, QA, Project Management, and Tendering teams for technical and execution issue resolution.
• Accountable for new product development (NPD) and introduction of new manufacturing processes..
• Coordinated with the CAPEX team for shop improvement, NPD planning, annual budget finalization, and procurement of jigs, fixtures, and machines.
• Monitored and controlled Cost of Poor Quality (COPQ) below 2%, aligned with the company's strategic blueprint.
• Vendor Development and management of welding and allied processes
• Developed and controlled heat treatment processes for critical materials in compliance with ASME codes.
• Resolved complex metallurgical issues related to headers and critical materials during execution.
• Prepared and executed repair procedures, including RCA and corrective execution plans.
• Managed customer interactions at various stages of project execution.
• Led Lean initiatives such as Value Stream Mapping (VSM) and Action Workouts to improve process efficiency.
• Drove continuous improvement through Kaizen initiatives across the shop floor.
• Mentored and developed junior engineers and supervisors for future leadership roles.
• Core team member for successful ASME certification.

• Researched on the field of Transient Liquid Phase diffusion bonding on the joining of Cu-Al
• Handful of experience on Field Emission Scanning Electron Microscopy, Scanning Electron Microscopy, Energy Dispersive X-ray spectroscopy, Optical emission spectroscopy, optical Metallography, and X-ray diffraction

L&T Research work

• Failure analysis of weld metal to identify the mode of failure. – Study of the welding of 1.47/3 high-temperature ferritic steel using different filler metals. Applied in reputed journal for publication. Under review. Advanced material characterization techniques used are Field Emission Scanning Electron Microscopy, Scanning Electron Microscopy, Energy Dispersive X-ray spectroscopy, Optical emission spectroscopy, and optical Metallography.

• Joined Alstom India Limited as a Young Engineering Graduate & worked as a Welding Engineer.
• Worked with welding processes including GTAW, SMAW, FCAW and SAW for boiler and pressure part applications.
• Preparation of WPS, PQR, & WPQ as per ASME and IBR and approval from IBR and customer.
• Prepared detailed heat treatment instructions for both furnace stress relieving and local post-weld heat treatment (SR), along with weld plans for shop execution.
• Reviewed and approved heat treatment instruction reports for shop execution.
• Verified and reviewed heat treatment charts to ensure compliance and job quality before customer offering.
• Conducted weld monitoring and surveillance to ensure strict WPS compliance during fabrication.