Dipl.-Ing. Madhav Kuruppath

Project lead – Process optimization and scrap reduction. Identified and implemented possible changes. • Achieved 20% scrap reduction by implementing changes following a root cause analysis using process mapping, CE Matrix, FMEA as tools. • Facilitated cross functional communication and information flow- between different locations to solve existing issues. • Defined and stabilized tool life at processes (eg: grinding, inspection.)

Process and equipment optimization. Designed and performed experiments - made changes that reduced the scrap produced due to polishing process by 50%. Stabilized visual inspection function – Increased repeatability and reproducibility, each by 10%. Established standards and trained visual inspection personnel. Facilitated intercompany technology and information transfer.

Comparative analysis of formability and work hardening characteristics of two variants of Aluminium alloy for can end manufacturing. (Master’s thesis Project) Characterized and analyzed the can body material alloy AA 3104 H19, can end material AA 5182 by mechanical testing (tensile, bulge, stack shear and earing tests). Created a working 3D can end shell forming model in LS Dyna using an anisotropic law to demonstrate the differences in formability properties of two can end (AA 5182) alloy variants.

Provided mechanical maintenance support for the scale up of metallurgy projects from experimental to pilot phase. • Designed, facilitated fabrication, setup and commissioned custom-made pressure vessels, heat exchangers and other equipment. • Managed manpower and resources during plant shutdown. • Planned, scheduled and carried out preventive maintenance operations.

Main modules: Forming technology, Materials technology, Machining technology, Fundamentals of Robotics. Laboratory work in tensile, Nakajima and compression testing.