Chenna Rayudu

Successfully installed and commissioned a continuous mesh belt furnace from the ground up, transitioning the project from setup to full-scale production. Designed and implemented Standard Operating Procedures (SOPs), Work Instructions, and Control Plans in alignment with ISO 9001 quality management standards. Achieved a record production output of 490MT per month OPE - 80% (M16&M20 Bolts & Nuts) by strategically grouping and sequencing components for efficient hardening and tempering operations. Ensured consistent metallurgical quality and zero rework through close monitoring of process parameters — temperature, belt speed, Cp values, gas flow, SCR/VFD control, and quenching performance. Initiated and implemented 5S workplace management practices to improve organization, safety, and operational efficiency on the shop floor. Led Kaizen initiatives focused on process optimization, energy reduction, and downtime minimization, resulting in measurable productivity gains. Contributed to OPE (Overall Production Efficiency) improvement projects, increasing machine uptime and throughput while maintaining product quality. Coordinated with the maintenance department for timely troubleshooting and execution of the preventive maintenance plan, reducing unexpected stoppages. Planned and managed manpower allocation, ensuring optimal resource utilization and adherence to daily production targets. Partnered with the Quality Assurance team to validate hardness, microstructure, and process conformance as per material and grade specifications. Promoted a continuous improvement culture, emphasizing safety, discipline, and skill development among team members.

Operated batch and continuous furnaces. Conducted hardness tests (HRC/HRB) for quality assurance. Reduced downtime through effective data monitoring and root cause analysis. Supported QA for hardness and microstructure validation.

Oversaw furnace operations for various grades (B7, B7M,L7,L7M). Controlled furnace atmosphere and quenching parameters. Ensured compliance with production and process control sheets. Conducted preventive maintenance on SCRs, VFDs, Heaters, and thermocouples.

Operated and monitored furnace cycles. Oversaw furnace operations for various grades (8.8, 10.9, 12.9,) Assisted in production scheduling and process adjustments. Maintained reports on production, downtime, and maintenance.

70.04%

80%

79.11%