Sushil Thapa
Jharsuguda
Summary
Process control specialist with over 16 years of expertise in 1.85 mtpa aluminium smelter operations at Vedanta Aluminium Limited.
Overview
17
17
years of professional experience
Work History
Senior Process Controller
Vedanta Aluminium Limited
Jharsuguda
06.2009 - Current
- Managed and optimized production processes to ensure efficient operations and Quality Control.
- Working as a Shift Incharge for Quality Control of Billet, ROLLING INGOT, T ingot, WIRE ROD and INGOT operation.
- Demonstrated clear understanding of quality procedures and documentation processes.
- Possessed knowledge of conducting internal audits on processes and products.
- Strong grasp of Failure Mode and Effect Analysis(FMEA).
- Ability to prepare and update CONTROL PLAN, STANDARD OPERATING PROCEDURES(SOP).
- Strong understanding of PPAP(Production Part Approval Process), MSA(Measurement System Analysis), SPC(Statistical Process Control).
- Strong grasp of customer specific PPAP requirements.
- Structured approach to complaint analysis and root cause investigation.
- Strong understanding of Metallography, Alscan and Podfa results.
- Strong grasp in effects of Parameters to achieve 100% recovery of patented American Wagstaff Direct Chill Aluminium castings.
- Managed operations and adjusted process parameters for composition and production.
- Resolved casting defects to achieve highest quality and finish of billets, contributing to product excellence.
- Controlling the Heat treatment process of Billet production for five homogenized chambers and two cooling chambers.
- Involved in inspection of standard cutting of 5.8 mtrs.Billet and surface defect.
- Involved in controlling (Fe: Si) ratio and electrical conductivity of 9.5 mm diameter of Wire Rod Coil.
- Coordinated with team to reduce scrap generation during Cast House operations, enhancing overall production efficiency.
- Gained familiarity with Podfa analysis techniques for quality assessment.
- Gained familiarity with Alscan analysis to evaluate material quality.
- Experienced in using Einsteins Ultra sonic machine to detect any internal cracks in Billets.
- Experienced in using PHASED ARRAY AUTO UT inspection.
- Achieved NDT UT level 2 certification to enhance inspection capabilities.
- Detailed Knowledge in Furnace preparation, Casting and Homogenization of Aluminium Billets.
- Experienced in Quality inspection of Billets by checking the surface defects of Billets i.e Bow, Perpendicularity, Length Variations, Composition Mix up etc.
- Experienced in detecting and reducing casting defects of Billets Like Out of Air Slip, Vertical Tear, Horizontal Tear, Run Out, Bleed Out, Blisters etc.
- Experienced in handling composition and preparation of different alloys like 6063, 6082, 6005, 1100, 3102, 3003, 3103, 6503, 1050, 1060 etc.
- Preparing and maintaining Excel sheets of Production related documents.
- 1.85 MTPA Aluminium Smelter of Vedanta Aluminium Limited, a group company of Vedanta Resources.
- Awarded with 'TECHNICAL Star' for my role in the Cast House PROCESS CONTROL.
- Collaborated with a team to reach the highest production levels of billets in a single day.
- Involved in Six sigma project on reduction in molten aluminum (yellow belt).
- Involved in KAIZEN project for reduction in expenses on Silicon and magnesium in Billets.
- TEAM leader in QC project for 'Reduction in TiBAL consumption'.
- Been a part of quality improvement project like reduction in rejection %age of Billets.
- Involved in Six Sigma project on reduction in Specific energy consumption of Homogenizing Furnaces.
Education
NDT (UT) Level 2 - Non destructive testing (UT)
Trinity Institute
Bengaluru02-2022
PDIS ( SAFETY) -
CHINMAYA INSTITUTE OF FIRE AND SAFETY
01-2018
Graduation(Phy Hons) - Physics
Government Autonomous College
03-2009
Higher secondary -
De Souzas School
03-2006
Matriculation -
Sri Aurobindo’s School
03-2004
Skills
- Quality control
- SPC (Statistical Process Control)
- Production process optimization
- Process optimization
- Excel expertise
- Proficient in Microsoft Office
- Diploma in computer applications
Accomplishments
- Awarded with 'TECHNICAL Star' for my role in the Cast House PROCESS CONTROL.
- Part of a team which achieved highest production of Billets in a day.
- Involved in Six Sigma project on reduction in molten aluminum (yellow belt).
- Involved in KAIZEN project for reduction in expenses on Silicon and magnesium in Billets.
- TEAM leader in QC project for 'Reduction in TiBAL consumption'.
- Been a part of quality improvement project like reduction in rejection %age of Billets.
- Involved in Six Sigma project on reduction in Specific energy consumption of Homogenizing Furnaces.
- Among the top three rank holders while completing the Bsc course in Physics.
- My Academic career has been first class till date.
- Executive Member of University Arts Club.
- Team member of the University Cricket Team.
Languages
- ENGLISH
- HINDI
- ORIYA
Extracurricular Activities
Executive Member of University Arts Club. Team member of the University Cricket Team.
Disclaimer
I hereby declare that the above written particulars are true and complete to the best of my knowledge and belief.
Professional Details
Senior Process Controller, Vedanta Aluminium Limited, Aluminium Smelting, Date of Joining-8th June, 2009
Personal Information
- Marital Status: Married
- Father's Name: Kancha Thapa
- Mother's Name: Late Meena Thapa
- Spouse name: Priya Rana
- Children: 1 Son
- Date of Birth: 08/10/89
- Gender: Male
- Nationality: Indian
Timeline
Senior Process Controller
Vedanta Aluminium Limited
06.2009 - Current
NDT (UT) Level 2 - Non destructive testing (UT)
Trinity Institute
PDIS ( SAFETY) -
CHINMAYA INSTITUTE OF FIRE AND SAFETY
Graduation(Phy Hons) - Physics
Government Autonomous College
Higher secondary -
De Souzas School
Matriculation -
Sri Aurobindo’s School