Summary
Overview
Work History
Education
Skills
Timeline
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Ajay Shirali

Pune

Summary

Highly accomplished Senior Mechanical Engineer and Project Leader with 30+ years of global experience in aerospace, automotive, and critical infrastructure electrification (Ports & Maritime, Airport GSE). Proven track record of driving over €650M+ in project revenue and scaling divisions by 260% through strategic mechanical design, project engineering, and tooling innovation. Expert in sustainable infrastructure solutions (Shore Power, PCA, 400Hz), PLM, advanced CAD/CAM (SolidWorks, CATIA, AutoCAD), DFMEA, GD&T. Well-versed in industry standards such as IEC/ISO 80005, AS9100, TS 16949, and APQP for global engineering compliance. Seeking to leverage deep technical expertise and cross-functional leadership to deliver high-efficiency, compliant engineering solutions.

Experienced with project planning, team coordination, and risk assessment. Utilizes strategic vision and effective communication to drive project success. Track record of fostering team collaboration and achieving project goals through adaptive leadership.

Overview

33
33
years of professional experience

Work History

Project Leader – Ports & Maritime & Airport Ground Support Equipment

Cavotec India Private Ltd.
01.2011 - Current
  • Spearheaded growth of Cavotec’s Ports & Maritime division by 260%, from €69M (2021) to €180.7M (2023), through modular electrification productization and strategic project execution.
  • Led detailed engineering and validation for a €17.5M pan-European Shore Power initiative, ensuring IEC/ISO 80005 compliance and integrating HV cable reels with shore-to-ship automation logic.
  • Managed global retrofit deployment for container ships (valued at €15.7M), focusing on onboard 80005 cable routing and shore connector panel design.
  • Engineered €6.2M turnkey PCA and 400Hz airport projects across India, UAE, and SE Asia, coordinating layout designs, pit systems, airflow simulation, and ducting accessories.
  • Authored 300+ technical documents including design drawings, interface layouts, test plans, and user manuals, managed via PLM (Teamcenter).
  • Developed standard component libraries for PCA systems and 400Hz supply chains, improving modular reuse rate by 42%.
  • Initiated sustainability-linked design updates that reduced total system power losses by 15% in new PCA units.
  • Reduced tooling costs by 18% through collaborative standardization of enclosure parts across product lines.
  • Piloted lifecycle-based scoring system for component selection, increasing part availability metrics by 30%.
  • Led value engineering efforts for PCA retrofits, cutting installation labor by 12% while maintaining IATA compliance.
  • Contributed to aircraft GSE (€6.65M) with PCA integration and rapid-disconnect hose retraction schemes.
  • Led technical specification writing and mechanical feasibility reports for RFQ/pre-bid stages on projects exceeding €25M.
  • Represented Indian R&D team in cross-continental design forums, fostering global collaboration and technical exchange.

Manager – Projects

Silicon Meadows Design Ltd.
05.2010 - 12.2010
  • Directed end-to-end new product development (NPD) and tooling projects for automotive and industrial clients, ensuring alignment with TS 16949 and APQP frameworks.
  • Managed complete lifecycle of GDC and LPDC component die development, including CAD modeling, CNC/EDM execution, and PPAP approvals.
  • Defined project scope, timelines, and resource plans; delivered critical milestones within cost and quality targets.
  • Published weekly development status reports and led daily internal reviews to drive progress and resolve risks.
  • Implemented continuous improvement strategies by integrating design feedback and tooling changes into workflows.

Engineer – ES&C Aerospace Division

Eaton India Engineering Center
01.2005 - 01.2010
  • Developed aerospace-grade components including aircraft-cockpit control panel assemblies, rotary switch enclosures, landing gear housings, and sensor brackets.
  • Utilized SolidWorks, CATIA V5, and AutoCAD to produce detailed 3D models, tolerance-based 2D drawings, BOMs, and exploded views.
  • Collaborated with US-based OEMs and EU certification teams to ensure AS9100 and DO-160G compliance for electrical and structural components.
  • Executed mechanical simulations and tolerance stack-ups to validate design safety and manufacturability.
  • Streamlined design workflows, reducing development cycles by 20% through continuous improvement initiatives.
  • Managed design data vaults using PLM tools and contributed to migration to enterprise-wide systems.

Sr. Project Engineer

Technocrat Industries Ltd.
01.2004 - 03.2005
  • Led on-site design engineering for Transbus International’s ENVIRO 400 Double Deck Bus in Leyland, UK, managing cross-border project delivery.
  • Produced 3D modeling, surface detailing, and assembly validation in CATIA V5-R11, ensuring fit, form, and manufacturability.
  • Designed tooling for plastic and sheet metal assemblies, including injection moulds and hot runner systems using CATIA V5-R12.
  • Managed end-to-end tooling lifecycle, from design input and vendor coordination to manufacturing trials and approval.
  • Collaborated with UK teams to align CAD packages and reduce rework cycles, improving first-pass acceptance.

Mould Engineer – Planning & Vendor Development

Precious Products (India) Ltd.
01.2002 - 01.2004
  • Supervised electrode path planning and CNC/EDM scheduling for precision molds; led a team of six engineers.
  • Handled procurement of mold materials (core/cavity steel, copper) and coordinated vendor machining schedules.
  • Managed CAD/CAM and fixture design for spark erosion and complex mold assemblies.
  • Oversaw end-to-end vendor interaction from PO to quality inspection and final delivery.
  • Streamlined supplier follow-ups and documentation flow between Toolroom, Stores, and Accounts for traceability.

Engineer – Techno-Commercial

Perfect Moulds Ltd.
01.2000 - 01.2002
  • Prepared cost estimates and feasibility analyses for injection molds using 2D prints, IGES files, and image inputs.
  • Collaborated with customers and internal designers to clarify technical specs and resolve tooling constraints.
  • Released validated designs for production in CIMATRON and PRO/E environments.
  • Coordinated with molders and QC for trial runs and customer approval.
  • Accelerated order finalization by improving turnaround on technical proposals and design iterations.

Engineer – Mould Design / Toolroom

Plastomech Engineers
01.1997 - 01.2000
  • Designed thermoplastic injection molds for automotive, consumer, and electronics sectors using AutoCAD R14 and MasterCAM R7.2.
  • Led full process cycle from raw material sourcing to mold fabrication and customer trial execution.
  • Managed 6 mold makers and 2 draftsmen to ensure adherence to delivery schedules and QA benchmarks.
  • Introduced design refinements in jigs/fixtures that minimized post-production rework and enhanced tooling reliability.

Toolroom Engineer

Premauni Tools
01.1993 - 01.1996
  • Oversaw manufacturing of molds for telecom, automotive, and defense clients; ensured accuracy through trial inspection and client feedback.
  • Collaborated with customers on pre-delivery trials and technical validation processes.
  • Assisted production teams to maintain dimensional quality and fitment compliance in high-precision assemblies.

Education

Bachelor's Degree - Engineering Technology

Birla Institute of Technology and Science
01.2016

Diploma - Tool and Die Technology

NTTF Dharwad
01.1993

Skills

  • Project scheduling
  • Project management
  • Risk management
  • Collaborative project development
  • Team motivation
  • Conflict management
  • Workload prioritization
  • Team management
  • Coaching and mentoring
  • Documentation and reporting
  • Project planning
  • Mentoring
  • Root-cause analysis
  • Effective work breakdown structure
  • Leadership skills
  • Multi-tasking skills
  • Collaborative mindset
  • Process improvement
  • Work Planning and Prioritization
  • Performance monitoring
  • Vendor selection
  • Time management
  • Problem-solving abilities
  • Detail-oriented
  • Decision-making
  • Relationship building

Timeline

Project Leader – Ports & Maritime & Airport Ground Support Equipment

Cavotec India Private Ltd.
01.2011 - Current

Manager – Projects

Silicon Meadows Design Ltd.
05.2010 - 12.2010

Engineer – ES&C Aerospace Division

Eaton India Engineering Center
01.2005 - 01.2010

Sr. Project Engineer

Technocrat Industries Ltd.
01.2004 - 03.2005

Mould Engineer – Planning & Vendor Development

Precious Products (India) Ltd.
01.2002 - 01.2004

Engineer – Techno-Commercial

Perfect Moulds Ltd.
01.2000 - 01.2002

Engineer – Mould Design / Toolroom

Plastomech Engineers
01.1997 - 01.2000

Toolroom Engineer

Premauni Tools
01.1993 - 01.1996

Diploma - Tool and Die Technology

NTTF Dharwad

Bachelor's Degree - Engineering Technology

Birla Institute of Technology and Science

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Ajay Shirali