Tamilarasan K

About Tamilarasan K

Senior Metallurgy Engineer with 7+ years of experience in automotive foundry operations, specializing in induction melting, cast iron metallurgy (Grey, SG, CG), and process optimization. Proven expertise in melting & product quality control, failure analysis, and new part development.Strong background in cost reduction, alloy optimization, energy efficiency, and furnace lining life improvement. Hands-on experience in carbon footprint reduction initiatives, including energy consumption monitoring, alloy minimization, process efficiency improvement, and EnMS (ISO implementation.Experienced in budget planning, raw material inventory control, SAP-based production & material management, and OEE improvement. Adept at root cause analysis (8D, CAPA), PFMEA, Control Plans, and IATF 16949 internal auditing.Passionate about sustainable manufacturing, operational excellence, and continuous improvement in high-volume automotive foundry environments.

Experience

1. Senior Engineer

   Brakes India

   Apr 2024 — Present · Sholinghur, IN

   Senior Engineer – Metallurgy | Foundry Operations (7+ Years)*Expertise in induction melting operations for Grey Iron, SG Iron, CG Iron, and ferro-alloy castings in the automotive sector.*Strong experience in process planning, production control, OEE improvement, and downtime reduction initiatives.*Hands-on in metallurgical & mechanical failure analysis, root cause analysis, 8D, CAPA, and customer complaint resolution.*Implemented and standardized Metal Stream Inoculation (MSI) and Adaptive Thermal Analysis System (ATAS) for quality consistency.*Led carbon footprint reduction initiatives through optimized melting practices, improved energy efficiency, alloy optimization, and reduction of material wastage.*Actively supported Energy Management System (ISO with focus on specific energy consumption (SEC) reduction and sustainable manufacturing.*Experience in furnace lining life improvement, charge mix optimization, and energy-efficient melting operations.*Successfully executed cost-reduction projects by alloy optimization, alternate material sourcing, and process improvements.*Responsible for budget monitoring and cost control related to raw materials, alloys, consumables, energy usage, and metallurgical inputs.*Involved in inventory planning and control, including raw material consumption tracking, stock optimization, SAP-based PR/PO activities, and material reconciliation.*Proficient in SAP systems for production entries, material management, and inventory control activities.*Internal Auditor for IATF 16949, with working knowledge of ISO 14001 & ISO 45001 integrated management systems.*Led process validation, PFMEA, Control Plans, SOPs, OPLs, and Six Sigma (DMAIC, Lean) projects.*Supported internal, customer, and third-party audits, management review meetings, and continuous improvement programs.*Demonstrated leadership as 5S Team Leader, promoting safety, Quality and operation excellence.

Education

• Government College of Engineering salem

  Bachelor of Engineering, Metallurgical Engineering

  2014 — 2018