Dhanabal M

Experienced Metallurgical and Heat Treatment Professional with 12+ years of expertise in metallurgical laboratory management, heat treatment processes, material testing, failure analysis, quality assurance, and continuous process improvement. Proven track record in automotive component manufacturing, ensuring compliance with international standards, customer specifications, and quality requirements. Skilled in metallurgical investigations, microstructural analysis, hardness testing, process validation, root cause analysis, and team leadership.

Strong knowledge of heat treatment technologies, laboratory accreditation requirements, and advanced quality tools. Adept at driving operational excellence, reducing defects, enhancing product performance, and supporting customer satisfaction through technical expertise and effective cross-functional collaboration.

Sr. Engineer – Metallurgist - Gnutti Carlo India Pvt Ltd

(2023-08)

• Lead Incoming Quality Assurance and Metallurgical Laboratory operations, ensuring compliance of raw materials and components with dimensional, chemical, mechanical, and metallurgical requirements.
• Provide technical approval for incoming materials and components based on metallurgical evaluation, dimensional verification, and customer-specific requirements.
• Manage Process Change Notification (PCN) submissions to customers for heat treatment supplier changes, alternate raw material sourcing, and manufacturing process modifications involving forging, casting, and steel suppliers.
• Drive resolution of metallurgical and manufacturing process issues through advanced root cause analysis, risk assessment, and implementation of sustainable corrective and preventive actions.
• Develop, standardize, and deploy Standard Operating Procedures (SOPs), process specifications, and control plans for Induction Hardening, Grinding, Shrink Fit, and related manufacturing processes.
• Lead closure of audit non-confaormities arising from CQI-9, IATF 16949, ISO 9001, customer audits, and internal assessments through effective corrective action management.
• Plan and execute internal heat treatment process audits, product audits, and CQI-9 self-assessments to ensure process robustness and compliance with customer-specific requirements.
• Review, approve, and verify supplier corrective action reports, ensuring timely closure of quality concerns and SAP quality notifications through effective supplier quality management.
• Champion Kaizen, Lean Manufacturing, and cost-reduction initiatives to optimize inspection activities, improve process efficiency, and reduce overall Cost of Poor Quality (COPQ).
• Develop, review, and approve raw material specifications for alloy steels, forged components, castings, and heat-treated products, ensuring compliance with design and performance requirements.
• Establish risk-based incoming inspection strategies and quality control plans aligned with customer drawings, critical characteristics, and product requirements.
• Ensure organizational compliance with customer-specific requirements and international standards including ASTM, ISO, DIN, JIS, BS, CQI-9, and automotive industry quality standards.
• Act as the primary technical authority for customer-facing metallurgical matters, including material selection, heat treatment validation, failure analysis, process qualification, and product performance optimization.
• Review and interpret customer drawings, specifications, standards, and engineering requirements to ensure manufacturing feasibility, regulatory compliance, and successful product realization.

Sr. Engineer – Metallurgist - L.G.Balakrishana & Bros Pvt Ltd

(2019-03 - 2022-07)

• Lead and manage the Induction Hardening Department, ensuring safe, efficient, and quality-focused operations.
• Develop and execute monthly and daily production plans to achieve customer delivery schedules and productivity targets.
• Drive cost optimization initiatives through process improvements, resource utilization, cycle time reduction, and energy-saving measures within the Induction Hardening facility.
• Establish, implement, and monitor process controls to ensure consistent product quality and compliance with customer specifications.
• Lead new product development activities related to Heat Treatment, Forging, SG Iron Casting, and Surface Finishing processes including Zinc Plating (Yellow Passivation), Blackening, and Trivalent Zinc Coating.
• Maintain and monitor compliance with Quality Management Systems, including ISO 9001 and IATF 16949 requirements, ensuring effective documentation and audit readiness.
• Conduct process capability studies, root cause analysis, and continuous improvement projects to enhance product quality and manufacturing performance.
• Provide technical leadership, mentoring, and training to departmental personnel while fostering a culture of continuous improvement and operational excellence

Engineer – Metallurgist - Stanadyne India Pvt Ltd.

(2017-04 - 2019-03)

• Act as the Department Management Representative (MR) and ensure compliance with Quality Management System requirements.
• Prepare monthly productivity reports and Management Performance Reports (MPR) for management review.
• Conduct failure analysis and root cause investigations for customer-returned and field-failure components.
• Lead New Product Development (NPD) activities, including preparation and submission of PPAP documentation.
• Initiate, coordinate, and monitor process validation and revalidation plans to ensure process capability and compliance.
• Maintain and control documentation related to BIQS Level III, ISO 9001, IATF 16949, and ISO 14001 management systems.
• Develop and qualify new suppliers for heat treatment, coating, plating, brazing, and raw material processes.
• Perform internal and supplier audits in accordance with ISO standards, CQI-9 (Heat Treatment), CQI-11 (Plating), and CQI-12 (Coating).
• Coordinate with suppliers and internal departments to ensure timely availability of consumables and input materials for uninterrupted production.

Joiner Engineer - Metallurgistaa - Renold Chain India Pvt ltd.

(2013-07 - 2017-04)

• Assisted in day-to-day operations of the heat treatment department, ensuring process parameters were followed.
• Supported failure analysis of heat-treated parts by collecting samples, documenting observations, and drafting preliminary reports; assisted in CAPA implementation tracking.
• Participated as an internal audit team member since 2016, conducting checklist-based audits and maintaining audit records.
• Supported heat treatment supplier audits by preparing documentation, assisting with audit checklists, and following up on action items.
• Assisted in new product development activities, including test planning, metallurgical evaluations, and compiling PPAP documentation.

BE - Aeronautical Engineering - Bannari Amman Institute of Technology (2013)

Diploma - Metallurgy - Annai J.J.K.K.SA Polytechnic College (2010)

S.S.L.C. - Government High School (2006)