Swanand Kulkarni

• Should Cost estimation of the products includes
• Complete and accurate reading of Engineering Drawing,
• Weight calculation and Yield calculation,
• Manufacturing Process Planning,
• Selection of operations (work centers) depending upon part design, material and market rates.
• Cost estimation of Robotic & Manual Welding, Manual assembly in MS Excel and aPriori.
• Costing of Sand blasting, Painting, Powder coating, ED coating on parts.
• Actively participating in VAVE sessions and Costing of VAVE ideas for cost reduction
• Estimation of Total Cost of Ownership & Support to the Purchase team for Source council presentation.
• Delivering of the Detailed Designed Process models with zero defects to the customer.
• Commodities handled Sheet metal, Light through Heavy fabrication components, Machining Components & Wiring Harness.
• Basic experience in product pricing.

• Completed technical estimates using cost models.
• MS Excel base costing of Sheet metal parts, Metal Wires, Metal Tubes, Metal Bar & Springs.

• Development of appropriate Domestic and Overseas supplier for new Product includes-
• Searching appropriate supplier based on Product requirements, sending request for quotations, Selection of the supplier, Feasibility audit, Negotiation on the cost drivers, Contract review, placing a Purchase Order, Systematic Follow-up with the supplier for delivering the product on agreed date.
• Finalizing of Rate contracts for service providing suppliers.
• Resolving technical issue occurred during development of the product by applying process knowledge.
• Resolving technical issues occurred during the fitment of the Routine and New developed components by applying appropriate technique with the help of supplier and design team.
• Assuring zero shortage on the production line by planning the future requirement in advance against schedule.
• Maintaining the work load at supplier end to keep his interest by detailed planning.
• Importing of products from Europe, Asia and United States.
• Commercial dealing with the suppliers from India and abroad.
• Conducting of Supplier Quality Improvement Program for quality improvement of products & shortening of lead time.
• Commodities handled- Fabrication, Machining, Sheet Metal, Mechanical, Non metallic & Electrical bought out parts.
• Materials handled- Mild steel, Stainless Steel, Aluminum, Acrylic, Rubber, Plastic
• Indirect purchase done for HVAC project for new store, Gear box for 3D Metal printing machine, consumables and Hardware.
• Preparation of various reports for management.
• Part rationalization & Supplier rationalization

• Should cost modeling of Fabrication and Machining assemblies using Costimator & TeamCentre software.

• Commodities handled Sheet metal, Light through heavy fabrication components, machining, casting, and forging.
• Development of Manufacturing and final inspection jigs and fixtures for prototypes and Developing components.
• Development of New prototype components and record keeping as per ISO.
• Cost estimation of new development components as per existing market rates.
• Implementing stringent Quality measures as per Standards & Specifications throughout the production processes to reduce Rejection / Rework levels and ensure higher Quality level and reliability of components in service.
• Conducting of Evaluation and Qualification audits of vendors. Vendor ratings as per ISO 9001:2000 and 2008.
• Developing, managing and monitoring the performance of multi-skilled work force through evaluation audits.
• Monitoring / Witnessing of Testing of variety of raw materials and welded coupons and Record Keeping of testing.
• Preparation and Controlling of Quality Assurance related ISO documents.
• Knowledge of Various welding processes as well as, WPS-PQR-WPQ, Testing of various raw materials.
• Preparation of Welder's Qualification related documents as per ASME & AWS such as WPS, PQR and WPQ.
• Conducting of Qualification tests of Welders as per ASME, AWS welding codes
• Conducting and Monitoring of Non-destructive tests for RAW materials as well as Welding such as D.P.T. M.P.T.; R.T; U.T. as per ASME and AWS.
• Inspection of Paint and Painted surfaces; Galvanized surfaces; Powder coated surfaces.
• Inspection of Surface preparation processes such as sand blasting, shot blasting.
• Documentation and Record keeping of ISO related documents (for Quality Assurance) such as MIS, Defect Trend analysis.

Notable Accomplishments

Project Handled- Manufacturing of 80-Meter-Long Columns.

Independently handled project for 4 months at Trichy (Tamilnadu).

First time the company was manufacturing huge 80-meter-long columns at Trichy, Tamilnadu.

The project was running 4 months continuously.

Tasks performed during project-

• Inspection-Thorough and stringent Inspection of raw material, In-Process inspection, Inspection of Welding equipment, Inspection of various finish Welding processes (Welded components), Inspection of surface preparation (Blasting), Inspection of Painted surface.
• Expediting-Expedited the project by

Arranging Third party inspectors at inspection places immediately after Thermax internal inspection.

By doing In-process inspection without delay.

By Helping Contractors and Vendor's production department to plan the production as per Thermax and Third-party inspection dates.

Daily monitoring of Progress status of components for faster production.

By providing a various process related checklist to reduce the rework.

By keeping Fluent and effective communication with the vendors and Thermax management.

• Project Planning-

Timely arrangement of transport vehicles by communicating with Thermax management for inspected components.

Updating of progress status of components to Thermax management every day for smoother future planning.

• Performed quality inspections and drafted reports to detail non-conforming material issues.
• Contributed to root cause analysis to determine core reason for failures and errors.
• Researched and evaluated new techniques and technologies to improve product quality.
• Reported on non-compliance issues and other negative factors discovered during production.
• Escalated concerns about project and process quality, referring discovered issues to engineering manager for correction.
• Developed and implemented comprehensive quality assurance program to guarantee organization products met safety and quality standards.
• Executed operational audits and assessed company operations, compliance and other associated risks.

Notable Accomplishments -

• NON-DESTRUCTIVE TEST LEVEL-II Certification in ULTRASONIC TESTING, MAGNETIC PARTICAL TESTING, AND DYE PENETRANT TESTING.
• INTERNAL AUDITOR Certification for Integrated Management System. (ISO 9001:2000, ISO 14000, OHSAS)
• SAP (ERP)-Quality Module certification.
• INDEPENDENT WORKING WITH VENDORS.