Jaypee_ Prabahar

To work in a dynamic and result oriented atmosphere which provides challenging & Opportunity for learning resulting in continuous development of organization.

Assistant Manager – Manufacturing Technology - Pitti Castings Pvt LTD. - Hyderabad, TG

(2024-12)

Tools used: Solid Works 2025 & Magma V6.1 Soft tool.

• Modeling & Methoding of Mining trucks Components
• Modeling & Methoding of General Electrical Motor case
• Modeling & Methoding of Railways supporting Components
• Modeling & Methoding of Pump Castings
• Key Responsible for Feasibility Study to RFQ with Business Development Team
• Ensuring Method Modelling & Basic and Stress Simulation at Magma V6.1
• Costing for Tooling Manufacturing & Layout Designing, Modelling discussion with Tooling vendors
• GANTT Chat Preparation for Sampling to Circulate with CFT team & Follow-up at Every stage process
• Monitoring Before & After Cast Process with production team to meets Scheduled
• Bulk Parts Review for improvement of Quality & Process Cost Saving, Weight Reduction at Regular production castings
• Increasing yield, First time Right & Reduce Weld Rods Consumption, Sand Metal ratio at bulk part productions
• Reduce the internal rejection of casting, Casting defect Analysis with Magma Simulation Soft Tool with Reverse Engineering
• Manpower management with pattern shop team to release planning patterns
• New Technology trials conducts at Methods, Materials for R&D to improvement of Quality, Cost Saving Purpose

Technical Support - Methods - Bradken India PVT LTD. - Coimbatore, TN

(2024-02 - 2024-11)

Tools used: Solid Works 2014 & Magma V5.6 Simulation Software.

• Modeling & Methoding of Mining part (Liner, Grinding mill, Crawler system & Buckets)
• Technical Solution & Development of New Products Development with Global R&D team (Canada, Malaysia & Australia) by using & Analyzing at Magma V5.6 Soft
• Freezing of Methods to Release & To Development of Tooling with vendors & Follow-up inspections plan to receipt of tooling as per scheduled plan
• Co-ordinate with Pattern shop team to fix-up Rigging system & PTMS to Production team
• Releasing operational process sheets to Production & Ensure the process of sampling with casting follow-up team
• Ensure & Recording Molding & Pouring Process at before cast
• Follow-up casting with sample follow-up team after cast for soundness validation of Castings
• Ensuring BOM & update requirements the same to planning team for continuous production of monthly planning
• Monthly plan undertaken to cost saving by increasing Yield & Sand metal ratio
• To be conduct weekly meetings with technical & Process follow-up team to meets sampling & release plan to productions

Junior Manager Development - SAMCO METALS & ALLOYS PVT LTD. - Vellore, TN

(2022-03 - 2024-01)

Tools used: Solid Works, AutoCAD & Solid Cast Simulation Software.

• Feasibility Study of Drawing for New product development (RFQ) & ECN creation, Work order validation and Pattern Layout
• Cost Estimation of New product development including Pattern & Core Box, Pattern vendors Follow-up
• Carry out Methoding for the New products & Validate through Solid cast Simulation, verifying mounting card for pattern mounting clearance
• Pattern Inspection & Method Mounting Inspection both in-house & outsourcing to pattern development
• Responsible to PTMS for pouring & Ensure the Molding Process, Mold Closing & Pouring process
• Follow-up Outsource - fettling, NDT & Machine Shop
• Closely follow-up for new development parts & work with customer to complete PPAP, APQP documentation & Submission
• Offering sample product casting to customer & Ensure the OTD
• Work on Root Cause Analysis, Disposal Action and Preventive Action for Customer complaints, NCR (internal & External) & 8D report to close Effectively
• Analyze of High weld rods items on bulk for review to improve the quality & Yield Optimization on bulk products

Development Engineer (Design & Development) - PEEKAY STEEL CASTING PVT LTD. - Coimbatore, TN

(2019-04 - 2022-02)

Tools used: Solid Works, AutoCAD & Magma V5.5 Soft Tools. Projects Undertaken: Modeling & Methoding of Mining & Engineering Component Parts, Railway Supporting Component, All types of Valve Castings (Gate, Globe, Swing, TOVP, Butterfly, Knife Edge Valves)

• Performing feasibility Study of drawing & Making layout design with varies machining and process allowance with which the pattern model is carried out & RFQ
• Model inspection & Core print clearance carried out for preparing model inspection report to give clearance for pattern & Core box Tooling
• Manually method Calculation done to find out feed modulus & Building 3D model with feeder neck, feeder, chills, running system design using SolidWorks
• Simulation flow study analysis of various casting components using simulation software Magma Soft v5.5
• Analyzing Variable parameters which includes Hotspot FS Time, Porosity, Niyama Criteria, Filling temperature, Velocity, Air Entrapment, Fractional Liquid, Feeding Characteristics & Core gas prediction Etc.
• Preparing Method Mounting Sketch with all required details for method mounting purpose to pattern makers once pattern inspection cleared
• Preparing Method Card with Product Data Sheet which includes Sleeves, Chills, running system Designs Etc., to the Production team
• Verifying Core & Mold making, Witness the Mold Closing & Pouring for Ensure the production process
• Follow-up the Sample in Varies Stages like Knock-Out, Fettling, Dimension Inspection & RT
• Designing 2D, 3D Conceptual model with technical specification (GD&T)
• Clearing the Customer & Internal NCR Effectively
• Follow up High welding rod & High runner items by 80-20 Principle with Enough data & Coordinate with Quality, Process Control team
• Working for Every month KPI/KRI Follow-up for department

Method Engineer (Methods & Development) - AMSTEEL CASTING PVT LTD. - Hosur, TN

(2016-06 - 2019-03)

Tools used: SolidWorks & AutoCAD, Magma Soft V5.1 Tools. Projects Undertaken: Design & Development of All types of Valve Component, Mining & Rocket, Military Equipment.

• Making 2D Drawings, 3D Modeling, Assembling, Drafting of parts using SolidWorks
• Developing Pattern & Core Box Drawings for Existing & New development items
• Carried out Prediction of feed modulus by using Magma Soft V5.1 & Proceeds Methoding of Feeder neck, Feeder, Chills, Gating System by Using SolidWorks
• Analyzing the casting Soundness by using Magma Soft v5.1 & Verifying parameters of Fractional Liquids, Porosity, Hotspot FS Time, Niyama Criteria, Etc.
• Preparing Feeder pad, Lettering approval Sketch & One-time Dimensional Approval deviation to Customer if requires
• Ensure the molding process, Pouring & Liquid weight Calculation to Pouring for production
• Follow-up Sample casting and clear the NCR for allows pouring Bulk
• Given out Successful Project from ISRO Casting component of AGITATOR which is used in mixing of propellant in rocket Engine by Optimization using Magma v5.5
• Designed & Assembled Rod Straightening Machine with successfully for reduce time for Straitening rod Manually in Molding Shop floor
• Successfully solved to pour LMW of 8.5T Massive casting in Foundry where the Melting Furnace Capacity Maximum was only 7.5T by Optimizing iteration of Methoding Using Magma V5.5
• Introduced Hot Topping Pouring by Optimization of Running System & Ladle of 3T Junky Flange TOVP Casting
• Elected to the Position of Team leader for Human Resource (HR) in ANOKHA TECH Fest-2016 held in college

Solid works Training Professional - Technovation Training center - Coimbatore, TN

(2016-02 - 2016-05)

Bachelor of Engineering - Mechanical Engineering - Hindusthan Institute of Technology (2012 - 2016)

HSC - SPK Matriculation Higher Secondary School (2012 - 2012)

SSLC - Govt.Boys.Hr.Sec. School (2010 - 2010)