Santosh Kumar Mahto

Standards and Specifications: Establish and maintain rigorous quality standards for copper and inner-grooved tubes, adhering to industry norms (e.g., ASTM, ASME), customer specifications,

In-Process Quality Control: Monitor key process parameters during tube manufacturing (extrusion, drawing, grooving) to maintain dimensional accuracy, surface quality, and mechanical integrity.

Defect Analysis and Corrective Action: Investigate any quality deviations or customer complaints, perform root cause analysis, and implement corrective actions to prevent recurrence.

Quality Management Systems: Implement and maintain quality management systems (e.g., ISO 9001 , ISO/IEC 17025:2017) to ensure consistent quality and continuous improvement.

Final Product Inspection: Conduct thorough inspections and testing of finished tubes, including dimensional checks, visual inspection for defects, pressure testing, and leak testing.

Material Development: Explore new copper alloys or surface treatments that can enhance the performance, durability, and corrosion resistance of the tubes in HVAC applications.

Yield Improvement: Implement strategies to maximize the yield of finished tubes from the raw copper material.

Environmental Impact: Develop and implement environmentally responsible manufacturing practices to minimize the environmental footprint of tube production.

Lean Manufacturing Principles: Apply lean manufacturing principles (e.g., 5S, Kaizen) to streamline production processes, eliminate waste, and improve overall efficiency.

Quality Control Systems: Implement and oversee robust quality control systems throughout the production process, including inspection, testing.

Compliance and Certification: Ensure adherence to relevant industry standards, customer specifications, and environmental regulations. This may involve obtaining and maintaining certifications like ISO 9001.

Laboratory Management: Oversee the operation and maintenance of the quality control laboratory, ensuring it is equipped with the necessary tools and staffed with qualified personnel.

Setting Quality Standards: Establish and enforce stringent quality standards for raw materials, in-process materials, and finished ferrochrome products. This involves defining acceptable limits for key elements like chromium, carbon, phosphorus, sulfur, and other impurities.

Product Development: Explore opportunities to develop new ferrochrome alloys with improved properties or tailored to specific customer needs.

Yield Optimization: Implement measures to maximize the yield of ferrochrome from the raw materials used in the smelting process.

Product Development - Collaborated with R&D and engineering teams to
develop new steel products or improve existing ones.
Quality Control - Responsible for full quality assurance and control for
alloy steel products with new customer approvals of various steel grades
like Automobile sectors etc.

Customer Complaint Handling - Receiving and documenting customer
complaints about steel products' quality or performance and providing
timely and appropriate responses.
Business Excellence - Process optimization, Quality Management, Identifying and mitigating risks, Cost control, Meeting standards and regulations, continual improvement (Kaizen and Lean practices),
sustainability practices (adopting environmentally friendly practices, reducing carbon emissions) and lastly Innovation and Technology.

Responsible for making manufacturing feasibility reports against
Technical delivery condition, Test Sampling Plan, Heat Allocation, and technical services (Customer complaint handling & services)
Developed new grades with approvals from automotive OEMs.
ISO 9001 QMS, ISO 14001 EMS, ISO 45001 OHSAS & IATF 16949 Documentation, with RDSO approval
Responsible for all customer complaints handling at WRM Black and Bright bar with root cause analysis and CAPA.
Inclusion rating, Microstructure, Decarburization, Jominy, Grain size, Carbide segregation, Charpy impact test, Macro-structure, Yield strength.
Handling all customer audits with necessary documents and approvals.

SMS Lab setup (OES and LECO machines) & Bar Mill lab setup with all mills testing requirements with BIS licensing and ISO certification from Base level in ESL Steels Ltd.

NABL and ISO accreditation of SMS and Mills lab from base level.

Responsible for controlling all rolling parameters in Rebar rolling, testing of all mechanical properties of finished products which includes UTS, hardness, hardenability, upset ability, developing of microstructure, grain size & inclusion for further development and study of product.

Process control in Steel Melting Shop (LD Converter, LRF & CCM) and rolling mill lab properly testing the macro report of Billet and other physical properties then proper declaration of grade.

Process control in Steel Melting Shop (EAF-LRF-VD-CCM) and properly testing the macro report of Billet and other physical properties then proper declaration of grade.

All Metallurgical testing - Mechanical testing, Jominy Hardenability, Impact, Grain size, Microstructure, Inclusion rating, Step down test & Macro test.

Implemented new quality assurance and customer service standards.

Making Manufacture feasibility reports and Test certificate.

Internal auditor for TS 16949 and ISO 9001 QMS.