Deepak Senapati

Carbon Pultrusion Specialist

• Develop and optimize carbon pultrusion process parameters to ensure consistent and high-quality production of carbon fiber-based products.
• Effectively manage and operate creel systems to ensure the smooth feeding of carbon fiber rovings into the pultrusion process.
• Expertly handle various diameters of carbon fiber materials, ensuring precise control and alignment throughout the pultrusion process.
• Responsible for the coiling and packaging of pultruded carbon fiber products, guaranteeing proper handling and storage to maintain product integrity.
• Skilled in resin mixing composition, ensuring accurate formulation of resin materials for enhanced product performance and structural integrity.
• Utilize Quality Data Analysis (QDA) techniques to monitor and analyze key process parameters, ensuring compliance with industry standards and specifications.
• Proficient in utilizing Microsoft Dynamics 365 (D365) to streamline warehouse operations, including inventory management, tracking, and order fulfillment.
• Develop and implement Power BI dashboards to visualize and analyze production data, enabling data-driven decision-making and continuous process improvement initiatives
• enhanced product quality, reduced waste, and increased production efficiency. This has resulted in substantial cost savings and improved customer satisfaction.
• Troubleshoot any operational issues, taking immediate corrective actions, conducting root cause analysis, and implementing preventive maintenance measures to optimize production efficiency.
• Effectively managed the creel system, ensuring proper feed and tension control of carbon fibers.
• Implemented strategies to optimize fiber utilization and minimize waste, resulting in improved process efficiency.
• Conducted routine inspections and maintenance of the creel system to prevent downtime and enhance productivity.
• Developed and conducted training programs for new operators to ensure compliance with best practices in the creel process.
• Implemented best practices for packaging and storage of coiled products to prevent damage during transit or storage.
• Proficient in monitoring and adjusting coiling parameters such as speed and tension to meet product specifications.
• Developed a thorough understanding of the process parameters and temperature requirements in carbon pultrusion.
• Proficient in monitoring and controlling parameters such as resin viscosity, line speed, and curing temperature.
• Collaborated with engineering teams to optimize process parameters for increased product yield and quality.
• Proven track record in efficiently detecting and addressing defects in carbon pultruded profiles.
• Developed expertise in using visual inspection techniques and non-destructive testing methods to identify defects.
• Implemented corrective actions such as adjusting process parameters, modifying die designs, or improving material handling procedures to prevent recurrence of defects.
• Collaborated with quality assurance teams to develop and implement defect prevention strategies.
• Provided training and guidance to operators on defect detection and corrective action procedures.
• Adhere the process by following the work instructions and checklists
• Maintain the tools and equipment by doing the autonomous maintenance on daily basis
• Monitor and control processes using visual observation, process data and line parameters
• Identify the problems in processes, products, equipment and work for solution
• Collect hazardous or non-hazardous waste in correctly labeled barrels
• Do the continuous improvements for improving the safety, quality and delivery
• Following the 5S standards in work area
• To look for Production & manpower planning Operation conducting productivity analysis troubleshooting
• To do a meeting with the PPC team to archive the production plan
• Responsible for achieving daily/monthly production targets
• To coordinate with the QA department to produce defect free parts
• Apply 7QC tool technique, 5's, 5M, KAIZEN, TPM and POKA-YOKE to reduce the muda & increase productivity
• KAIZEN activates for Production and Quality Improvement
• Responsible for final inspection of various checkpoints
• Achieving Production target with Quality
• WHY WHY analysis to find out the root cause of internal and external customer complaints, In-House Rejection, M/C Breakdown
• Responsible for the tool change and tool setting a per tool life of M/C
• Responsible for JOB training to new operators and maintaining all training records
• Responsible for maintaining the line inventory using internal logistics
• Production preparation and morning meeting (Communication about previous day abnormalities and change points discuss today's production plan.)

Overall, my experience in the carbon pultrusion die process, creel process, coiling process, parameters, temperature control, and defects detection has allowed me to become a skilled professional capable of optimizing production efficiency, ensuring product quality, and driving continuous improvement initiatives.Ensure production area is safe to work, productive and has required inventory

• Receive LNG from IOCL (Indian Oil Corporation Limited India), Ennore Terminal Chennai
• Unloading 17 tons of liquid LNG through mobile tanker to LNG bullet tank using cryogenic submersible pump
• Monitoring the overall LNG plant controlling through Rockwell Automation SCADA CONTROL Program
• And also operating through Allen Bradley PLC system
• There are three LNG storage tank, each tank capacity 212kl, in those tanks we storing the LNG liquid under temperature -162 degree Celsius
• Per day we are unloading 14 no's of mobile tanker and maintaining 200 tons in our LNG tank
• Also we are using atmospheric vaporizer (5000m^3/hr) to convert liquid LNG to Gas LNG under certain pressure
• Pure LNG GAS will provide to furnace for firing process up to 6.5 bar pressure using PCV(Pressure Control Valve).

• Thoroughly inspect incoming materials, identifying any surface defects or contaminants that could affect the coating processes.
• Utilize various pre-treatment methods, such as degressing, chromatizing, phosphating , passivation, & activation to prepare surfaces for coating application.
• Coordinated and executed the surface pre-treatment process for a variety of materials, including sheet metal parts, tubular parts and casting parts, ensuring optimal adhesion and corrosion resistance.
• 3+ years of experience in shot blasting and pre-treatment cathode electro deposition techniques.
• Proficient in operating and maintaining shot blasting equipment and machinery to clean and prepare various surfaces.
• Extensive knowledge of surface preparation methods such as abrasion, grit, and shot blasting techniques.
• Expertise in cathode electro deposition process, including pre-treatment, surface activation, and deposition of protective coatings.Work closely with the production team to ensure the timely completion of pre-treatment processes, aligning with production schedules.
• Monitor and adjust pre-treatment equipment settings, such as temperature, pressure, and chemical concentration, to maintain optimum performance.Production targets report submitted End of shift report circulation.
• Applied powder coatings to various products using electrostatic spray guns, consistently delivering flawless finishes within specified thickness and color requirements.
• Conducted thorough inspections of coated products, identifying and addressing any imperfections or inconsistencies to meet rigorous quality standards.
• Collaborated with cross-functional teams to develop and implement improved pre-treatment and powder coating methods, resulting in enhanced productivity, efficiency, and cost-effectiveness.
• Maintained a clean and safe working environment, adhering to all safety protocols and regulations associated with surface pre-treatment and powder coating processes.
• Trained and mentored junior technicians on surface pre-treatment techniques, including surface cleaning, degreasing, and chemical application, fostering a skilled team proficient in delivering high-quality finishes.
• Assisted in troubleshooting technical issues related to surface pre-treatment and powder coating, ensuring swift resolution to minimize operational downtime.
• Kept abreast of industry trends and advancements in surface pre-treatment and powder coating technologies, actively exploring innovative techniques to improve product quality and streamline processes.Process audit document maintaining
• Daily process & part rejection analysis. & Process audit document maintaining .Line inspection Final part Inspection and Spray Touchup.
• Quality check, production cost reduction
• Responsible for manpower management
• MSE plan, sequence planning according vehicle production
• Powder coating issue solving & aim to reduce rejection
• Production target supervising
• Production targets report submitted End of shift report circulation
• Daily process & part rejection analysis
• Process audit document maintaining
• Powder coating touch up booth handling, touch up gun maintenance
• Following Rework clearance.
• Achievements:

Costing:

1.Capacity increase in powder coating plant - 43L

2.Ceramic coating in powder coating oven - 31L

3.Powder coverage increased from 7 to 9 sqm/kg - 45L

Total saving-1.19Cr/Annum in 2022.

Quality: Inhouse PPM reduced from 5000 to 2000.

Delivery: On time delivery improved from 75% to 96%Booth maintenance