Anshuman Roy

- Seasoned manufacturing and materials science leader with over 25 years of experience, consistently championing Manufacturing and Quality excellence across automotive as well as EV sectors.

- Strong foundation in metallurgy and materials engineering, with a proven record of leading cross-functional initiatives to enhance product quality, optimize manufacturing processes, and ensure customer satisfaction.

- Strategic approach integrates critical thinking with data-driven decision-making, utilizing statistical tools to identify root causes, reduce variability, and drive continuous improvement.

- Recognized for building and mentoring high-performing operation and quality teams, establishing scalable quality systems, standardizing best practices, and embedding CTQ frameworks across design, development, and production stages.

- Demonstrated ability to align quality, design, and operational objectives with broader business goals, anticipate regulatory and product compliance challenges, and resolve complex production issues through sustainable solutions.

- Consistent track record of improving process efficiency, reducing waste, and enhancing product reliability.

- Strong contributor to organizational growth and customer trust.

- Academic qualifications include M.Tech. in Metallurgy and Materials Engineering from IIT Kharagpur and B.Tech. in Metallurgy from NIT Rourkela.

• Product Development & Manufacturing
• Material Selection & Process Optimization
• Design for Manufacturability (DFM)
• Design for Assembly (DFA)
• Quality Assurance
• Change Management & Process Improvement
• Team Leadership & Talent Development
• Supply Chain & Vendor Management
• Failure Analysis & Root Cause Analysis
• Battery & EV Technology Development

• Material selection and characterization – expertise in selecting materials across ferrous, non-ferrous, and polymer domains, with strong fundamentals in physical and mechanical property evaluation
• Welding technology and weld metallurgy – skilled in welding processes, metallurgy, and failure modes for structural and battery applications
• Steelmaking technologies and applications – in-depth understanding of steel production routes, alloy design, and downstream applications
• Non-ferrous alloy selection and casting technologies – competent in choosing and evaluating aluminum, copper, and magnesium alloys for cast and wrought applications
• Heat Treatment ( Ferrous and Non-Ferrous ) : In depth understanding and hand-son experience in both process an Product parameters optimization in Case carburizing, Carbo-nitriding, Induction hardening, Solutionisation and Aging of Non-Ferrous casting, customized thermal coating ( HVOF and Plasma ).
• Coating & Corrosion Engineering – Knowledge of electroplating, conversion coatings, corrosion testing, and mitigation strategies.
• Electrochemistry & Battery Material Characterization (LiB) – Hands-on experience in lithium-ion battery material testing, degradation studies, and cell chemistry evaluation
• Failure Analysis & Corrective Action – Strong diagnostic skills in root cause identification and implementation of effective CAPA strategies.
• SEM Image Analysis, Fractography and advanced Lab equipments – Proficient in scanning electron microscopy, fracture surface interpretation, and defect characterization.
• Supplier Quality Assurance – Application of APQP, PPAP, audit protocols, and performance monitoring systems.
• TS 16949 Quality Tools – Proficient in applying core quality tools for automotive manufacturing and supplier quality compliance.
• Value stream mapping and VAVE – application of lean tools for process mapping, waste elimination, and value engineering initiatives in product and process design
• Six Sigma (DMAIC) methodology – utilization of Six Sigma tools for structured problem-solving and continuous improvement in design and manufacturing processes
• Analytical Tools & Data Interpretation – Experience in data analysis tools for process validation and statistical correlation of test results.

• Structural Lightweighting of 3W/4W/EV Chassis Systems
  Engineered a 26% chassis weight reduction through strategic down-gauging using Advanced High-Strength Steels (AHSS: DP, FB) and Ultra High-Strength Steels (UHSS: Boron micro-alloyed), ensuring compliance with design stress thresholds and crash performance metrics.
• Lightweighting of 2W Chassis & Suspension Assemblies
  Redesigned steering assemblies (handlebars, clamps, bar holders) by replacing forged steel with high-strength aluminum alloy castings. Developed proprietary alloy chemistry and casting + T6 heat treatment route, delivering 20% weight savings with equivalent mechanical integrity.
  Introduced high-strength micro-alloyed tubular steels for chassis/column applications, optimizing stiffness-to-weight and cost-efficiency.
• Engine NVH Optimization via ADI Technology
  Applied Austempered Ductile Iron (ADI) for crankshaft and balancer shaft production, leveraging custom alloy formulation and controlled austempering. Achieved 10% mass reduction, 12% machining cost savings, and superior NVH damping over forged steel baselines.
• Deployment of Thermal Spray Coating for Powertrain Efficiency
  Implemented Air Plasma and HVOF coatings with engineered ceramic blends on engine components (e.g., liners) for thermal barrier and tribological functions. Enabled significant improvements in fuel economy, reduced friction losses, and extended component lifespan under thermal loads.
• Laser & Resistance Welding for EV Battery Systems
  Commissioned and validated in-house Laser and Spot Welding processes for Li-ion battery bus-bars and cell tab interconnections. Developed weld parameters, NDT protocols, and inline quality control systems for scalable EV battery production.
• Thermal Runaway Analysis of NMC Cells and having Design Guidelines and IQC for selection of Cells and validation of cells wrt chemistry and Cell manufacturing practices
  Simulated and validated thermal behavior of NMC battery cells under abuse conditions. Assessed passive and active mitigation strategies (material, structural design, venting) to improve safety compliance and thermal propagation control in battery pack architecture. Document Manufacturing Quality defects and test protocols for incoming cell inspection.
• Conversion of Aluminum Forgings to Castings for Critical 2W Components
  Redesigned key structural components from forged to cast aluminum alloy, maintaining mechanical benchmarks while achieving 15% cost savings. Optimized alloy chemistry, gating design, and multi-stage heat treatment in collaboration with foundry partners. Improved production throughput and reduced lead times without compromising component safety factors.
• Development of customized ENGINE OIL Lubricant ( Fully synthetic and Semi-synthetic ) for India and Overseas market: Development of dedicated Formulation of 10W30, 20W50, 10W50 and 10W40 Engine oil with long drain interval to have better engine life, fuel efficiency and generation of revenue from Royalty.