Rameshkumar Ganesan
Machining Expert
Chennai
Summary
Experienced professional with 19+ years in automobile manufacturing, specializing in machining, assembly, operations, new product development, and supplier development.
Specialized in cross-functional collaboration, supplier management, and continuous improvement initiatives. Held roles including Team Leader, Supervisor, Senior Supervisor, and Head of Department in Machining.
Skilled in system implementation and management standards including GK Management, ISO 9001:2015, ISO 14001:2015, IATF 16949, and VDI 6.5.
Overview
20
20
years of professional experience
7
7
Certifications
3
3
Languages
Work History
Head of Machining
Nemak Aluminium Castings India Pvt. Ltd.
02.2023 - Current
- Reduced Stellantis block leak rejections at the customer end from 12% to 0.5% by enhancing cubing-stage leak tester detectability through optimization of leak tester parameters.
- Increased Stellantis block machining output from 32 to 35 per hour by upgrading tool geometry for Ø24 mm bore and Ø5 mm oil hole operations, achieving a cycle time reduction of 23 seconds
- Developed combined fixture setup for Tata TC head and TGDI heads to eliminate setup change losses, thereby improving OEE and overall productivity.
- Managed new product development activities related to the machining line, including selection of machines, fixtures, and tools
- Calculated machining costs and provided proposals for product cost development
- Reduced machining cost by 10% for Tata head product through overall machining cycle time reduction
- Estimated cycle times and calculated tooling requirements for all new products
- Improved FIFO management by modifying the BS6 head machining line layout, eliminating unnecessary material movement.
- · Boosted Tata Heads machining capacity from 1,650 to 2,000 nos/day through installation of two CNC machines and Upgraded TGDI leak tester to enable BS6 head testing.
- · Identified suppliers for facility procurement, prepared RFQs, finalized technical agreements, and evaluated suppliers, machine selection, Fixture concept, Tool selection and production facilities (Parts conveyor, Gauge’s and Traceability)
Deputy Manager
Renault Nissan Automotive India Pvt. Ltd.
12.2011 - 01.2023
- Productivity improvement project: Completed the conversion of gearbox housing machining capacity from 1000/day with three-shift production to two-shift production, resulting in a 30% reduction in manpower and manufacturing costs.
- Hands-on experience in HMC (Mazak, Makino, NTC, and MAG), VMC (Makino, Fanuc, and Siemens), SPM machines, washing, and leak tester machining processes and problem-solving through root cause analysis
- Hands-on experience in Hobbing, shaving, broaching, and grinding machining processes and problem-solving through root cause analysis
- Steering member for product/process change management
- Certified as a GK Expert by Nissan Motor Co. India
- Setting up greenfield manufacturing facilities (machining and assembly lines) – Two Projects successfully completed as SSV role (Jxx & Sxx)
- Certified IMS ISO 9001:2015 and ISO 14001:2015 Internal Auditor by Nadhan & Co.
- Completed V-Pilot training and successfully completed two V-Up projects, with one receiving the Best V-Up Project award from Nissan Motor Japan.
- BEST QCC Project (machining rejection reduction) selected within RNAIPL and advanced to the Japan Global Competition.
Senior Engineer
TVS Motor Company
12.2005 - 12.2011
- Manufacturing process planning and process proving for machining engine parts (crankcases, covers, cylinder heads, and cylinder blocks) and vehicle parts (wheel hubs and brake panels)
- Plan and enhance the capacities of existing machining lines in plants to meet customer demand through various productivity improvements (e.g., Cycle time reduction, tool life enhancements, multi-model machining lines, Process sequence change and Combination tool)
- Experience handling vertical machining centers (VMC), horizontal machining centers (HMC), and SPM machines (washing, leak testers, and plug pressing)
- Customer complaint analysis and problem-solving through root cause analysis like Operation Missing, Dimension issue and Leak.
- Strong problem-solving skills demonstrated in daily manufacturing operations, including troubleshooting and resolving issues related to flatness, valve guide depth, valve guide runout, parent bore position, CMM report analysis, and process capability improvement
- Strong knowledge in machining model cell development, including chip mapping, process sequence optimization, process capability improvement, tool life enhancement, scrap reduction, and implementation of visual control systems.
Education
M.Tech - Manufacturing Management
BITS
Pilani, India05-2025
B. Tech - Mechanical Engineering
IGNOU
DELHI12-2011
DME - Mechanical Engineering
ARASAN GANESAN POLYTECHNIC COLLEGE
SIVAKASI, TAMIL NADU04-2005
Skills
Powertrain component manufacturing
Aluminum machining expertise
Experience in gearbox assembly processes
Lean manufacturing practices
Quality assurance management
New product line setup
Metallurgical heat treatment
Supplier relationship management
Cross-functional teamwork
Mechanical product development
Accomplishments
- Achieve daily production targets .
- Submit customer complaint analysis and corrective actions.
- Monitor rejection and take action to achieve quality targets.
- Manage manpower based on production volume requirements.
- Ensure machining cost control and achieve cost targets.
- Conduct feasibility studies for new programs.
- Prepare machining and tooling cost calculations.
- Implement modifications for existing products in machining
Certification
Metal Cutting Engineering Program from IMTMA
Timeline
Head of Machining
Nemak Aluminium Castings India Pvt. Ltd.
02.2023 - Current
Deputy Manager
Renault Nissan Automotive India Pvt. Ltd.
12.2011 - 01.2023
Senior Engineer
TVS Motor Company
12.2005 - 12.2011
B. Tech - Mechanical Engineering
IGNOU
DME - Mechanical Engineering
ARASAN GANESAN POLYTECHNIC COLLEGE
M.Tech - Manufacturing Management
BITS