VIVEK KUMAR

Key Responsible :-

Performed chemical analysis, hardness testing, tensile testing, microstructure analysis, cleanliness testing, and process control testing.
Conducted calibration, standardization, and preventive maintenance of laboratory instruments including Spectrometer, Microscope, Hardness Tester, and Tensile Testing Machine.
Managed incoming raw material inspection for wax, alloy bars, zircon flour/sand, crucibles, and other materials.
Performed HTF furnace CQI-9 assessments, SAT & TUS activities, and maintained related documentation.
Monitored critical process parameters including vacuum leak rate, moisture, coat thickness, water TDS, temperature, and humidity.
Coordinated with production, maintenance, quality, and suppliers to resolve process and quality issues.

Key Achievements
Successfully implemented in-house DM water plant regeneration, reducing annual operating cost by approximately ₹86,400.
Reduced customer report lead time by completing chemical testing and documentation within 3 days after V1.
Developed digital temperature and humidity monitoring records for better process analysis.
Repaired 3D printer in-house, eliminating external service cost.
Reactivated OMEC Particle Size Distribution Analyzer for zircon flour particle size testing.
Supported defect analysis and process improvement initiatives to reduce casting defects.
Conducted moisture testing, vacuum leak rate monitoring, prime coat thickness measurement, and process trials.
Maintained 100% compliance with laboratory safety procedures, PPE usage, SOPs, and mandatory training.

Training & Certifications:-
IATF 16949:2016 Internal Auditor Training
CQI-9 Heat Treatment System Assessment Training
Quality Management for Operational Excellence
Advanced MS Excel Skills
Professional Email Writing & Communication
Leadership
Trained laboratory assistants and contract employees on laboratory safety, testing procedures, and instrument handling.
Provided technical guidance for spectrometer operation, cleanliness testing, filter paper interpretation, ash content, moisture testing, and mold testing.

• Quality lab Inspection (All Four Wheeler CAR AND TRUCK / JCB Transmission Gear Manufacturing, TML, M & M, EATON, CARRARO INDIA, JHON DEERE, PUNCH POWER TRAIN and New Incoming Developments Gear Parts)
• Lab activities : Metallurgical testing of in house Heat Treatment Material Testing Raw Material like , Forging , Using Brinel , Rockwell Hardness Tester
• Documentation / Internal Audit / Process Audit / Customer Audit / ( CQI-9/ IATF AUDIT )
• Customer Complain Closed.
• Daily HT Production Up to date.
• Responsibility Consumable Purchase Indent (Requirement in HT.)
• QSR MEETING (Rejection submitted and find root causes / deviation / action plan etc.)
• New incoming induction and development part inspection coordinate with (NPD / Development / HOD in HT / Plant Head / GM) AND SUBMIT.
• Monthly Inventory update and submit to Plant Head and HT head )
• Manpower Handling, Welding Part Metallurgical inspection.
• Shift schedule weakly up to date etc.
• Knowledge in Induction machine 400 KW / 600 KW Mack by Inductotherm Group India.
• Laser welding Operation ( Customer :- Jondheere / Tml )

Key Responsible :-

Perform metallurgical inspection and validation of forged and heat-treated automotive components.
Execute heat treatment processes including carburizing, hardening, tempering, and quenching to achieve specified mechanical properties.
Conduct metallurgical testing such as case depth measurement, microstructure evaluation, grain size analysis, phase analysis, and hardness testing (Rockwell, Brinell, Micro Vickers).
Perform raw material verification through chemical composition analysis using Spectrometer/XRF and Jominy end-quench testing.
Manage phosphating line chemistry through titration analysis and ensure coating quality compliance.
Conduct CQI-9 process audits, internal quality audits, and support customer audits with proper documentation.
Maintain laboratory records, calibration status, traceability of samples, and test reports as per quality standards.
Perform inward inspection of castings and child parts for differential assemblies to ensure defect-free production.
Coordinate with Production, Quality, and NPD teams for process improvement, root cause analysis, and corrective actions.
Major Achievements:-
Led 2 New Product Development (NPD) projects for differential assembly components, ensuring successful metallurgical validation and customer approval.
Developed an in-house DM Water Inspection System, reducing corrosion risk and improving long-term component reliability.
Eliminated inspection bottlenecks by designing manual mould sample inspection fixtures, improving inspection efficiency and reducing validation lead time.
Improved laboratory quality by strengthening metallurgical testing procedures, documentation accuracy, and audit compliance.
Enhanced raw material verification and phosphating process control, resulting in improved product quality and reduced rejection.

• Quality lab Inspection (All Four Wheeler CAR AND TRUCK /JCB Transmission Gear Manufacturing, Tata Motors, Mahindra and Mahindra, EATON and New Incoming Developments Gear Parts)
• Lab activities : Metallurgical testing of in house heat treatment material testing raw material like casting , Forging, using brinel, Rockwell Hardness Tester, Metallurgical microscope, micro hardness tester chemical analysis image analyzer etc.
• Micro sample preparation of out batch in individual shift.
• To plan and allocate the man power for the activities and equipment or keeping in mind the Responsibility of full filling the production target.
• Maintaining heatness cleanliness with in the HT department.
• To plan the strictly follow the production schedule given by HT Manager.
• To check the record the metallurgical quality of products during and after order.
• MPI of heat treatment material, keeping record and send to final inspection.
• Update scrap In SAP, basic SAP knowledge like monthly production punching
• Keeping traceability and identification of material available in HT department.
• Heat code punching of material for HT.
• Follow up shot blasting of heat treated material and push the material machining / final inspections after shot blasting
• Involved activity like KAIZEN, 5S, etc.
• Personally working in case of man power issue and urgency
• Involve the maintenance and break down activity.
• Operating IPSEN Gas Nitriding furnace / Metallurgy inspection
• Sample (compound layer) (Annulus Gear & Ring Gear (TATA MOTORS)
• Update TC etc. check Root Dai, DIP, all parameters check or push to final.
• Check receiving steel shot then check hardness in (HV1).and inform our HT manger.
• All monthly production and metallurgy report update in TC (ERP Software also)
• Documentation Prepared for Audit , 1s and 2 s activity Proper Way.
• CALIBRATION AND TESTING ALL LAB EQIPMENT & FURNACE / QUINCHING
• Oil Testing & Document Up To Date (According to CQI-9 / IATF Guide Line).
• Coordinate With NPD Engineer for New Development Part, ( Like PUNCH POWER TRAIN / JOHN DEERE )
• Prepared and Updated: - SOP / WORK INSTRUCTION / CONTROLPLAN etc.

• Quality Lab inspection of (All Bajaj & TVS Gear and shaft testing surface hardness, Case depth etc. Of Heat Treatment.
• Carry Out Millipore Testing Like Measurement Of Fiber And Metallic Length Then Prepare production report.
• Maintain charge by test record in resistor for internal outside heat treatment.
• Coordinate with vender for H.T and Customer for their Queries.
• Working Knowledge all type of Hardness Tester, Brinell, Micro Vickers , Micro , MPI Crack Testing. UTM , ED Current Inspection
• Maintain TPM activities and Kaizen in Heat Treatment and Material Lab.
• Update Scrap in SAP, Basic SAP Knowledge like Monthly Production Punching.
• Involved Activity Like KAIZEN, 5S, etc.
• Induction Hardening, ( INPUT AND OUPUT MG SHAFT , STATER COUNTER ,AND CRANK SHAFT)