SANJAY KUMAR MAHALIK

Sr.QA/QC ENGINEER

Senior QA/QC Engineer with extensive expertise in managing quality control activities across diverse MEP systems in major construction projects. Proven track record of improving project delivery times by 20%, achieving a 95% success rate in initial testing, and ensuring compliance with stringent safety and quality standards. Committed to delivering defect-free installations and enhancing system reliability through meticulous documentation and problem resolution. Recognized for strong leadership skills and the ability to coordinate effectively with multidisciplinary teams.

Riyadh, Saudi Arabia
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Languages
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Skills
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Certifications
Work Experience
Site/Mechanical Engineer
Suhail Bhawan Group Holding LLC
Apr 2016 — Mar 2020SOHAR,MUSKAT, Oman
  • Built over 10 prototypes and conducted mechanical design analysis to resolve issues, achieving a 95% success rate in initial testing
  • Oversaw a team of 5 developing designs and technical specifications, which improved project delivery times by 20%
  • Produced designs using AutoCAD and Simulation CAD & CAM, reducing design errors by 30%
  • Conducted engineering evaluation tests, product and process capability studies, and quality audits, improving compliance scores by 15%
  • Forecasted project-related costs, materials, and labor needs accurately within a 10% margin, providing detailed cost-estimation reports
  • Eliminated malfunctions with recommended design modifications that reduced downtime by 25%
  • Developed and tested prototypes against requirements to validate designs before full production
  • Reduced operating costs by up to 15% by integrating sustainable designs and natural ventilation systems, contributing to overall project efficiency
  • Managed installation of HVAC systems, reducing energy consumption by 20% within [number] months
  • Conducted site inspections and assessments, identifying potential issues and reducing project delays by 2 days
  • Optimized maintenance protocols for machinery, decreasing downtime by 30% and saving the company [720] hours annually
  • CNC Operations — Supervised CNC machining activities including programming, tool selection, and machine setup.
  • Quality Verification — Ensured dimensional accuracy through precision measuring tools.
  • Production Control — Monitored machining cycles, optimized cutting parameters, and reduced downtime.
  • Fabrication Planning — Reviewed fabrication drawings, prepared cutting lists, and ensured material readiness.
  • Supervision of Cutting & Forming — Oversaw shearing, plasma cutting, bending, rolling, and fit‑up activities.
  • Workflow Management — Coordinated manpower, equipment, and daily production targets.
  • WPS/PQR Compliance — Ensured welding activities followed approved procedures and standards.
  • Weld Joint Inspection — Checked bevel angles, root gaps, and fit‑up before welding.
  • Welding Quality Control — Monitored weld quality, penetration, bead uniformity, and defect prevention.
  • NDT Coordination — Managed RT, UT, MT, and PT inspections for weld acceptance.
  • Material Preparation — Managed cutting, marking, and organizing materials before fabrication.
  • Drawing Interpretation — Ensured correct understanding of fabrication and assembly drawings.
  • Tool & Equipment Readiness — Ensured tools and machines were calibrated and ready for use.
  • Inventory Control — Monitored materials, consumables, and equipment availability.
  • Project Coordination — Coordinated with QA/QC, production, planning, and client representatives.
  • Quality Assurance — Ensured all activities complied with project specifications and standards.
  • Daily Reporting — Prepared DPRs, inspection logs, and progress updates.
  • Safety Enforcement — Ensured strict adherence to HSE guidelines.
  • Technical Issue Resolution — Identified and resolved site‑related technical challenges.
QA/QC Engineer
SHM under ONGC (Oil & Natural Gas Corporation Ltd)
May 2020 — Nov 2021Mumbai, India
  • Ensured compliance with QMS, ISO 9001, and project specifications.
  • Reviewed and approved Method Statements, ITPs, QCPs, PQPs.
  • Verified vendor qualifications and material certificates as per ASME/API.
  • Conducted internal/external audits and ensured closure of NCRs/CARs.
  • Implemented preventive actions through quality risk assessments.
  • Performed inspections for piping, welding, fabrication, mechanical equipment.
  • Ensured strict compliance with approved Inspection & Test Plans.
  • Conducted material receiving inspections for grade, size, and certification.
  • Verified installation of pumps, valves, tanks, vessels, compressors.
  • Conducted dimensional checks, alignment verification, and fit‑up inspections.
  • Supervised piping spool fabrication, fit‑up, and welding activities.
  • Prepared test packs and monitored hydrotest/pneumatic test activities.
  • Inspected installation of mechanical equipment and static packages.
  • Cleared mechanical and piping punch lists.
  • Ensured QA/QC activities followed HSE standards and PTW requirements.
  • Ensured compliance with ASME, API, ASTM, ISO codes and project specs.
  • Documentation & Reporting
  • Prepared WIR, MIR, NCR, CAR, test reports, inspection logs.
  • Managed Aconex submissions, transmittals, and approvals.
  • Submitted daily/weekly quality progress reports.
  • Prepared final QA/QC dossiers and handover packages.
  • Coordinated inspections with client, consultant, and subcontractors.
  • Resolved site quality issues and provided technical support.
  • Ensured subcontractor compliance with project quality requirements.
  • Ensured compliance with WPS/PQR and welder qualification requirements.
  • Conducted weld joint inspections (root gap, bevel angle, alignment).
  • Monitored welding parameters, electrode handling, and weld quality.
  • Coordinated RT, UT, MT, PT, PMI, hardness testing.
  • Managed weld repairs and ensured proper documentation.
HVAC Site Engineer
Al Turki Enterprises LLC
Oct 2021 — Nov 2022SOHAR, Oman
  • Coordinated HVAC installations based on building layouts, materials requirements, and synchronized with other crews
  • Provided emergency repairs for malfunctioning HVAC systems
  • Ensured compliance with safety regulations during installation and maintenance
  • Installed, maintained, and repaired residential and commercial HVAC systems
  • Implemented automation systems for centralized HVAC control
  • Advised customers on energy-efficient heating and cooling solutions
  • Diagnosed and resolved HVAC malfunctions using advanced diagnostic tools
  • Interpreted blueprints and schematics to install HVAC systems accurately
  • Supervised installation of AHUs, FCUs, VRF/VRV units, exhaust fans, fresh air units, chillers.
  • Managed GI/PI duct installation, including fabrication, alignment, sealing, and supports.
  • Oversaw copper piping, brazing, insulation, pressure testing, and refrigerant charging.
  • Executed CHW piping, valve installation, supports, flushing, and hydrotesting.
  • Interpreted HVAC shop drawings, IFC drawings, and coordination drawings.
  • Coordinated with civil, electrical, plumbing, and fire‑fighting teams to avoid clashes.
  • Ensured timely availability of materials and equipment.
  • Prepared daily/weekly work schedules and monitored progress.
  • Conducted pre‑commissioning checks for electrical connections, rotation, dampers, filters.
  • Coordinated TAB activities for airflow, static pressure, and water balancing.
  • Ensured proper startup, performance testing, and commissioning of HVAC systems.
  • Ensured compliance with ASHRAE, SMACNA, SBC, and project specifications.
  • Raised WIR/MIR and coordinated inspections with QA/QC and consultants.
  • Supervised technicians, duct fabricators, pipe fitters, and subcontractors.
  • Ensured safe installation practices and compliance with HSE & PTW requirements.
  • Resolved site issues related to duct routing, equipment access, and piping clashes.
  • Prepared DPRs, progress reports, and installation logs.
  • Assisted in preparing HVAC material submittals and obtaining approvals.
  • Updated as‑built drawings and final handover documents.
  • Managed HVAC‑related submissions and transmittals through Aconex.
QA/QC Engineer
Jindal Steel & Power Limited
Jan 2023 — Nov 2024India
  • Implemented and monitored mechanical works on site as per approved drawings, specifications, standards, methods, and safety rules
  • Ensured compliance with project specifications, drawings, and quality standards
  • Conducted inspections and tests identifying deviations or defects
  • Documented and reported deviations, coordinating corrective actions with project team
  • Completed numerous projects focusing on safety, quality, and efficiency in MEP & Construction engineering and project management
  • Inspected billets, blooms, coils, plates, and structural steel for chemical composition, mechanical properties, and certification.
  • Ensured heat number traceability throughout production.
  • Monitored rolling, cutting, shearing, and straightening operations for dimensional accuracy.
  • Checked furnace temperature, rolling speed, cooling rate, hardness, and surface finish.
  • Conducted in‑process QC to prevent defects like cracks, laminations, scaling, and undercuts.
  • Verified gauge, thickness, width, straightness, and surface finish of rolled products.
  • Conducted dimensional checks using micrometers, vernier calipers, ultrasonic gauges.
  • Coordinated mechanical testing (tensile, bend, impact, hardness) as per IS/ASTM.
  • Ensured compliance with rolling mill SOPs and quality standards.
  • Ensured compliance with WPS/PQR and welder qualifications (AWS/ASME).
  • Conducted fit‑up inspections for beams, columns, trusses, frames, and heavy structures.
  • Monitored welding parameters, electrode handling, and weld bead quality.
  • Coordinated UT, RT, MT, PT for weld acceptance.
  • Verified cutting, bending, rolling, and assembly of fabricated steel components.
  • Verified machining accuracy, tool wear, and tolerance compliance.
  • Conducted dimensional inspections using precision instruments.
  • Ensured correct installation of conveyors, cranes, motors, gearboxes, and structural supports.
  • Verified preventive maintenance activities and equipment reliability.
  • Prepared MIR, WIR, NCR, CAR, test reports, inspection logs.
  • Managed Aconex/EDMS submissions, approvals, and traceability.
  • Prepared final QA/QC dossiers and handover packages.
  • Maintained calibration records for gauges and instruments.
Sr.QA/QC ENGINEER
Al SAMMAN CONSTRUCTION LLC
Aug 2025 — PresentCurrentQIDDIYA, Saudi Arabia
  • As a QA/QC Engineer (MEP), I am currently working on the Dr. Sulaiman Al Habib – Paris Gallery Project in Al‑Olaya, Riyadh, where I am responsible for managing and executing all quality control activities for HVAC, plumbing, drainage, fire protection, electrical, and low‑current systems. My role includes preparing and submitting WIRs, MIRs, material submittals, and QA/QC documentation through Aconex, conducting site inspections to ensure compliance with SBC, ASHRAE, NFPA, IEC, and project specifications, coordinating with consultants and contractors to resolve technical issues, supervising testing and commissioning, closing NCRs, and ensuring all MEP works are delivered defect‑free and fully compliant for final handover.
  • As a Senior QA/QC Engineer (MEP), I am responsible for managing and executing all quality‑related activities across major projects including Qiddiya – SIX FLAGS Theme Park, Transport Hub, and the Diriyah Project – Six Senses, working in coordination with main contractors UCC and Al Bhawani (BUJV). My duties include reviewing and implementing ITPs, method statements, and QA/QC plans, conducting inspections for HVAC, CHW piping, ducting, plumbing, drainage, fire protection, electrical, and low‑current systems, and ensuring full compliance with SBC, ASHRAE, NFPA, IEC, IPC, IMC, and project specifications. I prepare and manage WIRs, MIRs, NCRs, SORs, and oversee testing and commissioning of all MEP systems, including pressure tests, flushing, balancing, electrical testing, fire alarm loop testing, and system integration.
  • I coordinate closely with consultants, main contractors, and subcontractors to resolve technical issues, close punch lists, and ensure defect‑free installations. I also manage complete QA/QC documentation through Aconex, including shop drawings, material submittals, transmittals, test reports, and final handover dossiers. My role includes leading the preparation of as‑built documentation, redline drawings, and ensuring all MEP systems are fully tested, commissioned, and handed over successfully to the client.
Skills
Quality AssuranceQuality ControlProject ManagementTechnical SupportAutoCADLean ManufacturingTest Plan DevelopmentContinuous IntegrationCustomer RelationsTeam SupervisionProblem SolvingCommunicationAuditing techniques knowledgeQuality Management SystemsExcellent time managementSix Sigma CertificationMaterials science knowledgeSafety consciousnessMEP Quality Control WIR PreparationMethod Statements Reading & interpreting drawings Testing & commissioning knowledgeMaterial compliance verification Root cause analysisAconex & Documentation ControlMaterial Submittal & ComplianceConsultant CoordinationSite Supervision & Quality ControlProblem Solving & Root Cause AnalysisSoft Skills Companies ValueITP Review & Implementation NCR ManagementMaterial Submittal Compliance MEP Codes & StandardsSite Inspection SkillsTeam TrainingRisk Assessment & Preventive Quality ITP & Method Statement ReviewLeadershipAdaptability Continuous LearningAI Literacy CNC PROGRAMINGDecision‑MakingFULL KNOWEDGE OF WELDINGCNC MACHINING & MASTER CAMSIMULATIONKATIACEROFULL KNOWEDGE OF CUT & BEND DEPARTMENTFABRICATIONSSHEET METAL OPERATIONS
Education
Bachelor of Technology (B.Tech), Mechanical Engineering
P.M.E.C Government Collage, Odisha, India
POST DIPLOMA (PDTDM), Tool Design & Manufacturing, CAD/CAM
CTTC.BBSR INDIA
Diploma, Mechanical Engineering
BALASORE SCHOOL OF ENGINEERING,Odisha, India
ITI (FITTER)
Industrial Tanning Institute,2 YEARS
MBA, Essential Management Skills
International Business Management Institute, Berlin, Germany
Certifications
ISO 9001:2015 - Quality Management System (QMS)
Essential Management Skills
Entrepreneurship Development Program Certification
SIX SIGMA White Belt & Yellow Belt Training Certification
ISO 9001:2015 Certified Lead Auditor
Effective Leadership Certified
HP foundation
Languages
English
Fluent
Arabic
Intermediate
Hindi
Native
Bengali
Advanced
ODIYA
Native
TELGU
Intermediate
Accomplishments
Gold Medal in B.TECH Mechanical Engineering
Gold Medal in Diploma (All Odisha)
1st Prize in Minor Project (Multi Purpose Agricultural Machine)
Qualify written test, practical test, module test, ISRO Ahmadabad, Gujarat (February 2015)
Debate competition 1st on 2023 (Pmec.college)
Group Discuss completion 1st 2023 (Pmec.college)
Topper in Mechanical Branch 2024
Essay Writing completion 1st 2024
GK competition 1st 2024
Recitation junior 1st on 2007
Debate competition 1st on 2006
Debate competition 1st on 15th August 2005
GK & Quiz competition 1st on May 2008
State level mono action 2nd on 2008
State level mono action 2nd on 2006
Jay Durga club Anantapur mono action 2nd on 2005
Annual sports 11th finance commercial Tentei Gram Panchayat Soro Mono Action 3rd on 2003
Block mono action 3rd on 2005
District level senior drawing 3rd 2008
Block level mono action 3rd 2006
Medanta Medicity (New Delhi) running competition 4 kms, 3rd on 2012
State level youth festival 2014 (Samjdhar Jodi 2nd 2014)
References available upon request.
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