Rajkumar Katiyar

Foundry Head with 30+ years of working experience managing and producing 2800 tons of good castings per month. Expertise in metallurgy, manufacturing and development of S.G Iron Castings, Cast Iron, Steel Castings, and their Heat Treatment. Managing two manufacturing units with 500+ workforce.

Expertise in handling HPML, Arpa, No Bake, Alfa Set, Shell Moulding, and Co2 moulding lines. Proficiency in manufacturing casting weights from 0.3 kg to 3500 kg. Strong background in plant operations, production management, quality assurance, process improvement, and customer relationship management.

Foundry Head (Production, Planning, Quality Assurance, Process Improvement, Machining, Lab, Dispatch & Customer Interaction) - M/s KIE Engineering - Haridwar

Managing 2800 tons casting per month, handling 6 moulding lines and 7 induction furnaces. Responsible for patterns and methoding, production and planning, metallurgy, moulding, NPD, customer interaction, maintenance management and controlling metallurgical properties of C.I and S.G castings as per grade on SINTO-HPML moulding, Disha 900, ARPA 450, and core machines (Cold box, No bake, Shell core). Lab testing includes sand and metal testing.

Focus on rejection reduction and cost optimization with yield management.

• Production Plan, Schedule & Execute to meet Quantity, Quality & Delivery as per Target
• Track OEE & Productive Matrices to Manage & Optimize the Productivity of Plant
• Co-ordinate with Purchases, Planning & Marketing team for Raw Material & Dispatch Schedule
• Implementing & Monitoring KPI & addressing Variance to maintain Operational Excellence & Continuous Improvement
• Implementing 5S, Kaizen, TPM, Lean Manufacturing Activity
• Identify & Eliminate Process Wastage (Excessive Energy Consumption, Down time, Rework, Yield)
• Ensure all Products meet Customer Specification as per QAP & ISO 9001-2015 & IATF 16949
• Ensure Process Capability & Implement of Control Plans & Work Instructions
• Co-ordinate with Quality Teams to Proactively address Process & Product deviation & non-conformities using Cause Analysis (8D, Fish Bone & Pareto)
• Leading & Motivate Production Team to achieve Operation Excellence
• Implementing Team work & Collaborative work culture focus on Quality, Innovation & Safety measure
• Define KPI & Conduct Performance review for Production Team
• On the basis of Skill Matrices identify Skill games & Arrange Training program in Operation, Safety, Kaizen, Equipment, Lean Practice & New Foundry Techniques
• Co-Ordinate with Maintenance team to Approve for Preventive Maintenance Schedule & Review weekly basis
• Co-Ordinate with Maintenance to reduce down time of Equipment through Adherence of Check sheets, Audit & Training
• With Kaizen Activity initiative to identify & eliminate Non effectiveness points of Production process
• Analyze, Decide & Act on trend analysis, Variance analysis, Cause & effect analysis to facilitate solution for problem related to PQCDSM
• Implementing Lean Management Manufacturing Practice to enhance Production, reduce waste & reduce cost
• Using SAP/ERP System for Production planning, Inventory Control & Operations Report
• Monitoring & Analysis of Reports of Production Metrics including Efficiency, Down time, Rejection & Cost of Product
• Support in New Product development, PPAP, Castings Trial stream line in Production, Product validation
• Collaborate with Quality, R&D & Marketing Department for New Part Development
• Suggest to NPD team for Methoding of new development of Pattern & Improvement in yield
• Costing of New Product development & Cost Optimization of Running Castings
• Taking safety measure & Training to persons to maintain Work place towards zero accident zone
• Ensure compliance with Environmental Standard & Use the equipment's