Process Incharge optimizing shaft furnace and anode casting operations to meet production targets, copper anode quality, and process stability. Controls process parameters, metal accounting, and QA/QC root-cause actions while leading 12–14 operators across safety, housekeeping, and SOP compliance. Drives shutdown planning, audit readiness, and continuous improvement to reduce defects, downtime, and fuel use.
Work History
Process incharge
3 Years- Monitored and optimized daily process parameters to achieve production targets while ensuring copper anode quality and process stability.
- Controlled anode chemical composition and physical properties to meet refinery and customer quality specifications.
- Supervised shaft furnace and anode casting operations, enhancing molten metal handling and reducing fuel consumption for improved production efficiency.
- Led a team of 12–14 operators across production, ensuring 100% adherence to SOPs, housekeeping, and safety standards.
- Supported QA/QC initiatives through root cause analysis and corrective actions, resulting in higher refinery-compatible anode quality.
- Investigated and resolved casting defects, including mould release issues and anode weight variation, through root cause analysis and process improvements.
- Planned and executed plant shutdown activities, achieving timely completion and effective resource utilization while minimizing production downtime.
- Contributed to Continuous Improvement initiatives (CIP, SGA, and CCQC) focused on process optimization, quality enhancement, and cost reduction
- Reduction of barite layers on anode which helps in CE of Refinery
QA/QC Intern
5 Months- Executed project stabilizing mechanical properties of API X70 grade line pipe steel using thermo-mechanical controlled processing.
- Evaluated hardness and surface roughness of steel plates to ensure product quality and process consistency.
- Evaluated hardness and surface roughness of steel plates, ensuring adherence to product quality standards and process consistency.
- Contributed to metallurgical investigations, strengthening quality control measures for high-strength steel production.
- Collaborated with cross-functional teams to analyze process data, identifying improvement opportunities for continuous quality enhancements.
Student Intern
2 Months- Acquired hands-on experience in TMT bar manufacturing process, overseeing stages from billet reheating to dispatch.
- Examined rolling mill operations, thermo-mechanical treatment, and quality control procedures to support product excellence.
- Observed mechanical testing and dimensional inspection to uphold product quality standards.
- Partnered with production and maintenance engineers to deepen understanding of plant operations and implement safety best practices.
Education
Bachelor of Technology - Metallurgical and Materials Engineering
- CGPA: 7.44/10
Skills
Certification
- SAFETY: Execution of the work, whole plant safely, and till
- CRANE OPERATIONS: Certified EOT crane operator with proper training
- COURSERA: Fundamentals of project planning and management
- COURSERA: Basics of operational management
Languages
Professional Summary
Metallurgical Engineer with 3 years of experience in copper anode casting Plant, and process optimization. Experienced in production operations, quality control, continuous improvement (CIP, SGA, CCQC), and metallurgical process analysis. Proven track record of reducing mould rejection by 48%, leading cross-functional teams, and improving manufacturing efficiency through data-driven process optimization.
Relevant Coursework And Experience
- Operations Management
- Project Management & Process Optimization
- Production Planning & Process Control
- SAP Operations (Production & Inventory)
- Anode Casting Plant Operations
- Metal Accounting & Process Auditing
- Industrial Safety & SOP Compliance
- Quality Control & Continuous Improvement (CIP, SGA, CCQC)
- Team Leadership & Manpower Management
Plant Projects
Stabilization of API X70 Line Pipe Properties | AMNS India, Hazira | Jan 2023
- Optimized Thermo-Mechanical Controlled Processing (TMCP) parameters to stabilize the mechanical properties of API X70 line pipe steel.
- Analyzed the effect of processing conditions on hardness, ductility, and tensile strength.
CIP Project – 10% Reduction in LPG Specific Consumption | Sterlite Copper | Jan 2025
- Analyzed shaft furnace efficiency, burner air-fuel ratio, and heat losses to identify opportunities for reducing LPG/PNG consumption by 10%.
- Project still under progress and till now we are able to reduce upto 5% of fuel which gives us cost benifits of upto 1 CR INR annually
SGA Project – Reliability Improvement of Weighing Ladle | Sterlite Copper | Jan 2025
- Investigated weighing ladle failures and improved reliability by optimizing ladle tile material selection and maintenance practices.
- By this improvement we are able to save upto 24MT of tabcast and 1000MT of Production annually ,by this we get benefits of saving tabcast cost of 15lakh INR and fuel cost of 20lakh INR annually
Mould Life Improvement in Anode Casting Plant | Sterlite Copper | Jan 2026
- Analyzed the anode casting process and optimized post-casting procedures, reducing mould rejection by 48%.
- By completing this project we are able to save upto 70lakh INR annually on mould rejection cost
Reduction of changeover time for Intermediate ladle and weighing ladle | sterlite copper | jan 2026
- Analysed all the activities by maintenance team from production stopped to production started (around 7hrs)
- Eliminate the extra activities and by better utilising manpower and using preheated the ladles.
- We put the saving of 3 hrs of changeover time and additional production increase which is annually 500MT
ACP Anode Oxygen Reduction/Stabilization Project (Ongoing) | Sterlite Copper | Feb 2026 – Present
- Optimizing furnace charging practices, process parameters, and reducing agent additions to stabilize oxygen content in ACP anodes.
- Monitoring process performance to improve product quality and metallurgical consistency.
- We have reached upto the 50% of what our customer demanded about the oxygen parameters
Academic project
Development of Aluminum Matrix Composites from Industrial Waste | NIT Srinagar | Jan 2022
- Fabricated aluminum matrix composites reinforced with waste materials (tube glass, Cerawool, and fly ash) using the casting process.
- Evaluated microstructure, XRD, hardness, tensile strength, and corrosion behavior of the developed composites.
- Results in 30% increament in mechanical properties and 50% corrosion resistance increased
- Cost of making material is zero , so we save all our amount and completed the project without any expense
Key Achievements
- Reduced mould rejection by 48%.
- Led Quality Month team to 3rd Position.
- Selected to represent Sterlite Copper in CCQC Mumbai Chapter.
- 2 time Quarterly incentive Award winner for outstanding performance and CEO Kitty award winner
Leadership And Extracurricular Activities
Participant – CCQC Mumbai Chapter | Sterlite Copper, Silvassa | Aug 2026
- Representing Sterlite Copper in the CCQC Mumbai Chapter Competition with a process improvement project on Anode Weight Distribution, targeting 95% process consistency.
- Collaborating with a cross-functional team to compete among 73 organizations, 431 teams, and over 1,800 participants.
Leader – Quality Month Celebration | Sterlite Copper, Silvassa | Dec 2024
- Led a cross-functional team to secure 3rd place in the Quality Month competition through effective teamwork and problem-solving.
Member – Dhatu Mitra (Department of Metallurgical & Materials Engineering Club) | NIT Srinagar | Mar 2022 – Jul 2023
- Organized departmental technical and cultural events while actively promoting student engagement and teamwork.