Thaj Mathew Thomas -B.E, PGDIB, DBM, CSWIP, ASNT, SSPC PCI, ASQ, IRCA

Experience

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  Autofield Engineers Pvt. Ltd

  Dec 1997 - Dec 1999

  Manager IE (Industrial Engineering)

  Management Representative:-Prepare quality manual, procedures and work instructions for the company in line with QS 9000 requirements.Co-ordinate management review and provide input for the effectiveness of the Quality Management System.Develop and implement system and process audits including planning, execution, reporting and follow-up.Coordinate non-conformance management process, including systematic corrective action report (CAR) with root cause analysis, correction, and appropriate corrective actions. Industrial Engineering:-Establish labour standards and to resolve questions relating to job utilization and performance. Implement, ‘Lean Manufacturing’ to reduce waste or to increase profit by considering material travel, line balancing, inventory level, effective utilization of manpower and machines lay-out.Significant Accomplishments:-Reduced throughput time from- 13 days to 7 days.Increased Production Yield to 96.5% from 90.5 %.Task force team leader for trouble shooting and problem solving.Member of Non-conformance disposal committee and Management review committee. Show less

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  Sayuru Marine Transport Pvt. Ltd

  Dec 1999 - Aug 2001

  Business Manager

  Managerial:-Implement company policies and strategies and ensure these are very well understood and carried out by employees. Produce annual budgets from sales to net profit level in accordance with the timetable announced in each budget year and format advised by finance per Business unit.Annual Target Setting process; prepare plans and forecasts with periodic updates and revisions on annual target setting.Ensure the business units build strong relationships with customers and suppliers and develop new business leads and ideas in line with the current strategy.Commercial:-Ensure all existing customer and potential new customers are fully aware of the business unit and company service offer.Develop business measurement tools and analyze key financial and non-financial metrics.Operational:-Ensure all business is conducting in accordance with the company’s operational procedures.Ensure customer satisfaction through managing their shipments in the correct way and in accordance to the timeframe specified / agreed by the customer.Maintain strong and healthy working relationship with clients, banks and local Government. Show less

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  TDK Indonesia

  Aug 2001 - Sept 2009

  Quality Manager

  Key areas:-Quality Management / Lean ManufacturingQuality controlProduct EngineeringProcess ImprovementProcess ValidationResource ManagementSignificant Accomplishments:-Task force leader for the development RoHS Compliant (Pb-free) components.Distinction of transferring knowhow and setting up the production line at Zhuhai, China.Instrumental in designing & implementing lean manufacturing techniques in the production line.Stellar role in scrap reduction & rationalization of processes. Rationalisation cost reduction measurers-- Reduction of direct manpower and material cost , average 11 K euro / month- Scrap cost, average 17K euro / month- Inventory reduction- raw material/ WIP/finished product, 550k euro/ year Show less

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  Nippon Steel & Sumikin Engineering Co., Ltd.

  Sept 2009 - Sept 2014

  QA/ QC Lead

  Projects Involved: Tan Burrup Project, South Mahakam Well Head Platform Jacket & Topside fabrication, GB Well Head Platform Jacket & Topside, GB CPP Jacket fabrication of Premier Oil and Modec – BP Agola PSVM FPSO.Area of Focus:Integrated QHSE Management System:Adherence to ISO 9001:2008, OHSAS 18001, and ISO 14001 requirements.Procedures, instructions, and specifications alignment with technological advancements and cost containment.Support for subcontractor assessment in the supply chain.Quality Management System:Development, implementation, maintenance, and improvement of QMS and HSEMS.Production, review, and update of NSB procedures, work instructions, and specifications.Evaluation of supplier qualification, certification, and performance rating.Quality Control:Oversight of QC activities for Construction, Installation, Inspection, and Test of Topsides Modules.Monitoring inspection services, ensuring timely planning, execution, and completion by qualified inspectors.Coordination with fabrication team and NDT sub-contractor to address discrepancies and remarks.Liaison with clients and third parties to ensure timely completion of roles in the fabrication process.Continual Improvement:Monthly review of KPIs, analysis of variances, and identification of improvement opportunities.Reporting on quality surveillance activity outcomes and KPI achievements.Implementation of changes for better results.Initiation and implementation of training programs related to QMS, QA/QC, Welding, NDE, HSE, and AQIS.Significant Accomplishments:Authorization for vendor selection, evaluation, and approval.ASME-U, U2, and PP stamp(s) accreditation/certification.Certification of integrated ISO 14001:2004 and OHSAS 18001:2007.Introduction of a customer survey questionnaire (CSQ). Show less

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  SIEMENS Oil & Gas Solutions

  Oct 2014 - Apr 2016

  QA/ QC Manager

  Projects Involved: YAML LNG ESS Modules, Jangkrik Complex Project, YAML LNG ESS PAB modules, DSME and Upper Zakum E-House modules.Quality Assurance / Quality Management System:Developed and established Project quality plan, procedures, Inspection Test Plans (ITPs), Method statements, Work instructions, Audit plan, and Key Performance Indicators (KPIs).Maintained the quality management system to meet project requirements and industry standards.Led audits for contractors, subcontractors, and suppliers across design, procurement, construction, and commissioning.Participated in lesson learned workshops and project risk review meetings, contributing to continuous improvement initiatives.Liaised with classification bodies for inspection, document approval, and obtaining final release certificates.Reviewed and managed weekly weld defect rates to meet stipulated KPIs.Prepared quality dashboards and trend analyses.Quality Control:Coordinated a team of 80+ QC personnel for planning, executing, and completing inspection and testing activities.Conducted project risk review meetings, calibrated measuring instruments, managed welder qualifications, and inspected materials.Oversaw sub-contractor management, pre-commissioning, commissioning, hydro and pneumatic tests, NDT, punch list, deviations/queries, function tests, product identification, and traceability.Reviewed piping layouts, isometrics, 3D models, and closed out comments for the Mechanical Discipline.Liaised with clients, subcontractors, and suppliers to support project goals.Led the Clean Build & Dimension Control program throughout the project lifecycle.Ensured inspection from pre-fabrication of isometric spool to mechanical completion and commissioning.Managed equipment installation, configuration, data management, performance monitoring, and systems administration.Reported MC progress periodically, tracking Inspection and Test Reports (ITRs) with punch status to the project team. Show less

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  RiSea Propulsion Group

  Oct 2016 - Mar 2019

  QA/QC Manager

  RiSea Propulsion Group is a renowned manufacturer specializing in Retractable Azimuthing Electric Podded Thrusters and Propulsion systems for marine vessels and submarine systems.Key Responsibilities and Achievements:Quality Management Enhancement:Developed and improved Quality Procedures, Inspection and Test Plans (ITPs), Factory Acceptance Tests, Final Dossiers, Operations Manuals, and Customer Survey Reports.Audits and Compliance:Implemented in-process and operational audits to assess process control and compliance with internal and customer requirements.Conducted regular and ad-hoc audits to enhance the quality system and verify the effectiveness of corrective and preventive actions.Cost Optimization:Successfully reduced project costs by 20% through rationalization projects.Implemented improvements in lead time, quality, production forecasting, and optimized manpower utilization.Team Management:Assigned work and provided direction to Site Quality Inspectors to ensure quality work processes and product confidence.Mentored a team of professionals focused on achieving quality excellence and compliance with Inspection Test Plans and procedures.Performance Monitoring:Evaluated quality metrics and provided reports to drive continuous improvement.Product Reliability Improvement:Improved product reliability through thorough inspection of free-issue materials, verification of sub-supply sources, welder qualification, welding inspection, NDT, dimension control, protective coating inspection, traceability, leak testing, factory acceptance test, mechanical completion, final inspection, and packing & preservation.Continual Improvement and Customer Satisfaction:Drove continual improvement through lessons learned workshops and project risk review meetings.Served as a trusted advisor in the customer's decision-making process.Maintained excellent communication and relationships with clients, resolving issues to enhance customer satisfaction. Show less

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  Golar LNG

  Jul 2020 - Jan 2023

  Site Quality Representative

  Area of Focus:Sub-contractor and vendor development for FLNG conversion construction.Sub-contractor pre-qualification audits.System and Process audits, including piping and structural fabrication.Quality management system (QMS) implementation.Inspection test plan (ITP), quality surveillance, and weekly meetings/reporting.Verification of sub-supply sources and inspection of free-issue materials.Welding and NDT procedures, welder qualification, and fabrication inspections.Dimension controls, NDE, traceability, PWHT, hardness test, load test, blasting & painting.Erection and installation of pipe spools, electrical and instrumentation equipment.Hydrotest, chemical cleaning, flushing, pickling & passivation, final inspection.Non-conformance, deviations, site queries, technical queries, and quality statistics.Principal Accountabilities:Conducting subcontractor pre-qualification audits and vendor QHSE evaluation.Early alignment with contractors and subcontractors on quality requirements.Coaching and supporting project QA/QC inspectors.Leading quality and safety joint walkthroughs.Initiating site quality surveillance reports (SQS).Issuing and following up on Non-conformance reports (NCR) and Corrective Action Requests (CARs).Participating in investigations and root cause analysis.Expediting closeout of inspection actions and project NCR corrective actions.Monitoring inspections from pre-fabrication to pre-commissioning.Verifying preparation of hydro test packs and approving.Conducting trend analysis and providing quality training and awareness.Contributing to project Quality KPIs, weekly & monthly reports, and lessons learned workshops.Identifying and handling unacceptable conditions, discrepancies, non-conformities, and opportunities for improvements.Leading Clean Build & Dimension Control program throughout the project lifecycle.Reviewing and approving project QA/QC documents generated by subcontractors and vendors. Show less

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  SEAQUEST ENTERPRISE PTE. LTD.

  Nov 2023 - now

  Quality Manager @ Saudi Aramco Marjan Project

  We specialize in comprehensive project management, engineering, procurement, fabrication, installation, testing, and commissioning services for architectural, HVAC, E&I, and piping works at McDermott yard in Batam. Notably, the company is involved in the MARJAN PACKAGE-1 OFFSHORE GOSP 4 DEVELOPMENT project for Saudi Aramco.Quality Management System (QMS):Ensure effective implementation of the company's QMS for delivering high-quality products and services throughout the project.Construction Quality Control:Verify that all construction quality control activities align with project specifications, contractual requirements, and relevant quality standards.Resource Management:Direct and control quality resources, ensuring recruitment and retention of well-trained staff, including Aramco approved supervisors and inspectors.Lessons Learned:Provide awareness on lessons learned, non-conformance reports (NCR), welder performance, and discuss challenges and mitigation plans on a weekly basis.Nonconformities:Respond to company notifications of defects and nonconformities, providing root causes, corrective actions, and agreed completion dates within 48 hours.Internal Audits:Conduct internal audits periodically, ensuring compliance with standards and procedures.Compliance with Standards:Ensure compliance with Saudi Aramco Engineering Procedures (SAEP), Saudi Aramco Engineering Standards (SAES), and Saudi Aramco Material System Specifications (SAMSS) in material requisition.Inspection Activities:Coordinate with inspectors or inspection agencies, raise Non-Conformance Reports (NCR), and reject non-compliant materials.Material Control:Supervise procurement and material controllers, ensuring timely delivery of planned activities as per project requirements.Verify inspection reports, Factory Acceptance Tests (FAT), prepare Final Disposition Reports (FDR), and issue release notes to Aramco in accordance with schedule Q requirements. Show less