Ram Donepudi

Manufacturing Quality and Analytics professional with 14+ years of experience across seamless pipe manufacturing, ERW pipe inspection, HFW pipe inspection, cold drawn products, square hollow sections, and rectangular hollow sections in Saudi Arabia and India. Strong background in quality assurance, quality control, NDT, process control, internal auditing, defect analysis, product cycle time analysis, and plant performance improvement within large-scale industrial environments. Experienced in combining hands-on manufacturing quality leadership with business intelligence, data analytics, and cost control to improve operational performance and management decision-making.

Skilled in using Power BI, DAX, SAP, MES, SQL, Python, and Excel to develop KPI dashboards, automate reporting, analyze process losses, monitor production trends, improve budget control, and support stock planning and material usage decisions. Proven success in delivering $1.2M+ annual savings through spare parts optimization, alternate vendor development, and data-driven procurement improvements. Demonstrated expertise in material stock control, planning support, CAPEX justification, OPEX control, process optimization, new product development support, implementation coordination, and cross-functional quality improvement.

Recognized for leading teams, improving operational transparency, strengthening compliance with API, ASTM, and SAMSS standards, and supporting product quality across seamless pipes, ERW pipes, HFW pipes, cold drawn tubes, square sections, and rectangular hollow sections. Additional strengths include borescope visual inspection and analysis, EDM notch cutting, SPC, RCA, CAPA, and final inspection management.

Manufacturing Quality & Analytics Lead / QA-QC Supervisor and Data Analyst at ArcelorMittal Tubular Products Al-Jubail (2017-05 – Present)

Lead quality, inspection, analytics, and operational reporting activities for seamless pipe manufacturing in a global steel manufacturing environment while managing a 35-member QA/QC team.

• Directed QA/QC operations and final inspection for seamless pipes, improving compliance with customer requirements, inspection effectiveness, and process stability in a high-volume manufacturing environment.
• Led a 35-member quality team through inspection planning, work allocation, process monitoring, and team coordination, strengthening execution discipline and shop-floor quality governance.
• Developed automated Power BI KPI dashboards using SAP and MES data, improving management reporting, production visibility, defect analysis, budget monitoring, and decision-making speed.
• Designed product cycle time analysis and downtime dashboards to identify process losses, improve machine utilization visibility, and support plant performance improvement.
• Implemented cost-center-wise budget monitoring and operational tracking aligned with production forecasts, strengthening cost control, OPEX visibility, and management planning.
• Supported material stock control and planning by analyzing spare parts consumption, operational usage trends, and production-linked requirements, improving stock visibility and control effectiveness.
• Reduced spare parts consumption through analytics-driven monitoring and process discipline, delivering $0.4M annual savings and improving material efficiency.
• Identified alternate global vendors and reduced OEM dependency through data-backed sourcing analysis, delivering $0.8M annual savings and strengthening procurement flexibility.
• Conducted SPC, defect trend analysis, root cause analysis, and CAPA to reduce recurring defects, improve process capability, and strengthen quality control.
• Performed internal auditing of inspection procedures, documentation practices, and process controls, improving compliance readiness and adherence to internal and customer quality requirements.
• Performed borescope visual inspection and analysis to assess internal surface conditions and support accurate acceptance decisions in critical pipe inspection applications.
• Supported EDM notch cutting activities for NDT validation, inspection calibration, and method improvement, enhancing flaw detection reliability and test effectiveness.
• Prepared data-backed CAPEX proposals and ROI justifications for equipment upgrades, plant renovation, and process improvement projects, supporting investment decisions and modernization plans.
• Supported new product development and implementation by coordinating quality requirements, inspection readiness, process checks, and production monitoring during product and process changes.
• Generated daily, weekly, and monthly reports from SAP and MES systems, improving communication, plant visibility, and management control over operational performance.
• Integrated quality, production, cost, and inspection data into review processes, strengthening operational strategy and data-driven continuous improvement.

QA/QC Representative at Maharashtra Seamless Ltd. / DP Jindal Group (2016-07 – 2017-04)

Performed inspection, quality assurance, process monitoring, and compliance support for multiple tubular products including ERW, HFW, cold drawn, and hollow sections.

• Executed incoming, in-process, and final inspection for ERW pipes, HFW pipes, cold drawn tubes, square hollow sections, and rectangular hollow sections, improving product conformity and compliance with customer specifications.
• Performed NDT, hydrotesting, mechanical testing, bend testing, and hardness testing using standard quality procedures, improving release confidence and quality assurance effectiveness.
• Monitored galvanizing, stenciling, and packing operations, improving process compliance and final product readiness for dispatch.
• Reviewed Material Test Certificates, inspection records, and related documents for accuracy and completeness, improving documentation quality and audit readiness.
• Monitored process and quality data to support defect analysis, process control, and production improvement, helping identify recurring issues and corrective actions.
• Coordinated with engineering and production teams to resolve quality issues using root cause analysis, improving corrective action effectiveness and operational continuity.
• Supported customer inspections, audits, complaint resolution, and consultant coordination, strengthening client confidence and compliance performance.
• Contributed to production planning and quality monitoring by tracking product conformity through all inspection stages and ensuring readiness for customer release.

QC Assistant Engineer - NDT and Final Inspection at United Seamless Tubular Pvt. Ltd. (2012-07 – 2016-06)

Supported NDT, final inspection, process control, and non-conformance management for seamless pipes and critical engineering components in a heavy manufacturing environment.

• Conducted online and offline final inspection of seamless pipes including casing, line pipe, mechanical tubing, and coupling stock, ensuring compliance with technical specifications and customer requirements.
• Performed advanced UT and ECT inspections using SONOTRON FB-340/76 and EDDYTRON FB-340/8 EC systems, improving defect detection capability and volumetric inspection coverage.
• Applied MPI, LPT, UT, dimensional inspection, and thickness gauging to pipes, billets, weld joints, shafts, castings, plugs, and FQM rolls, improving product integrity verification and final quality control.
• Conducted borescope visual inspection and analysis for internal quality verification and defect detection, supporting final inspection accuracy in tubular products.
• Supported EDM notch cutting for NDT reference preparation, validation activities, and inspection method improvement, enhancing testing reliability and flaw detection effectiveness.
• Coordinated with engineering, production, and project teams to improve dimensional accuracy, process control, and product quality in critical components.
• Supported continuous improvement by providing inspection findings, defect observations, and technical inputs to strengthen production quality and process performance.

Bachelor of Technology in Mechanical Engineering – CSJM University (2012)

Intermediate in MPC – PRSMN Junior College (2008)

SSC – Navodaya Vidyalayam (2006)