Ganesan S

My Self Graduate in Foundry Technology - 22+ yrs Foundry Experience with strong practical result oriented foundry men. Steel, Alloy Steel, Mn. steel, High chrome, Heat resistance steel, Cast Iron and S.G. Iron castings. Fully controlled & Practical working experience in Design, New Product Development, Methods and Quality.

Core Skills:
i. Design and Development of components for Castings from Automotive for Cylinder Block, Cylinder Head and Transmission Case, Earth Moving, Engineering, Wind Mill, Power plant and Cement Plant, with sound technical knowledge.
ii. Analyzing and troubleshooting the problems faced during Product Design & development, Designing, Manufacturing, Trails, and Production.
iii. Design and Manufacture of Sand Mould Castings.
iv. Design and manufacture of Jigs and Fixtures for Foundry.
v. Experience and exposure of sheet metal fabrication and techniques.
vi. Estimation and costing of foundry Tools like Pattern, Core boxes and Fixtures.
vii. Knowledge of Inspection methods and experience in using Inspection Instruments.
viii. Experience and knowledge of GD &T.
ix. Experience 3d models using Solid works.
x. Good Experience in 2D drawings using Auto cad.
xi. Exposure to Quality Managements Systems like ISO9001.
xii. Experience in DFMEA and FMEA of moulds.
xiii. Experience in Project Management.
xiv. Casting defects and solutions.
xv. Experience in C.I & Steel Foundry.
xvi. Experience in No back, Co2 and green sand moulding process.
xvii. Experience in Arpa, IMF Fast Loop Line, Hand Moulding and High pressure moulding line.

Quality Skills

1. Handling of all Quality Assurance related matters in Foundry & customer end
2. Daily Monitoring of Final Inspection with final inspectors/layout inspectors.
3. Casting Layout Inspection Plan & Status.
4. Analysis of Internal & Customer end Rejections on daily, weekly & monthly basis & taking corrective/preventive actions.
5. Handling of customer complaints and resolving the same to their satisfaction levels
6. Rework & Rejection finalization, Decision on deviations, Root Cause analysis of non conformances & implementation of corrective/preventive actions decided.
7. Implementing 7 QC Tools [Histograms, Pareto Charts, Cause and Effect Diagrams, Run Charts, Scatter Diagrams, Flow Charts, Control Charts
8. Prepare pattern design

Professional Experience Summary :

i. Prepere Pattern design
ii. Methoding of new castings such as Risering and Gating system.
iii. I am having experience gating system and Risering design of Steel, Gray Iron and S.G iron casting.
iv. Knowledge of magma simulation software.
v. Analyse sample progress.
vi. Follow sample procedure
vii. I am also involved in estimation of cost of castings, cost of patterns and cost of development charges for submitting quotations against enquiries from Customers.
viii. Moulding system Expertise: No back Fast loop line sand system, Green sand system, CO2 moulding & Core making – Cold box, shell core and Co2 cores.
ix. Also to make detailed Running and gating system drawing and design for pattern and core box design drawing.
x. Prepare of 2D and 3D drawings of varies Castings and Methods
for the indicating Gating, Runners and Risers for the casting required
for Automobile, Wind mill, Machine Tool, Earth Movers, Turbine
casting, Cylinder block, Cylinder heads, Gear box housing, etc,.
xi. Design of Patten and core box and Prepare Pattern and Core box drawings.
xii. 3D Part models with casting and machining configurations.
xiii. Designing the Pattern and core boxes using Solid works.
xiv. Mould, Spliting, Core cavity Spliting from the casting model using Solid works
xv. Surface Modeling and Assembly using Solid works.
xvi. Design of Gating and Running system drawings using Auto Cad
xvii. Design of mould boxes and Fabrication drawings using Auto Cad.
xviii. Prepare Method Card Drawings.
xix. Knowledge of NDT Techniques in RT / UT / MPI / DPI .
xx. Prepare work instructions and SOP of NPD castings.
xxi. Pattern Modeling, Core cavity, splitting and mould cavity to developed from Casting Model.
xxii. Products: Automobile, Earth Mover, Railway, Engineering, Cement Plant, Power plant, Wind Mill, Turbine, Machine Tool and Textile application casting.
Products weights: 150kgs to 7500kgs.