Bala kumar Manokaran
Senior Manager - Cost Engineering
Thoothukudi,TN
Summary
A results-oriented Senior Manager with 9 years of expertise in Cost Estimation, Should Costing, Carbon Emission Analysis, Product Development, and Process Improvement within the automotive and manufacturing industries. Specializing in VAVE (Value Analysis & Value Engineering), cost modeling, and cross-functional collaboration, with hands-on experience in tools like Excel-based Costing, Costimator, aPriori, TCPCM, and PLM. Proven track record in driving cost reductions and improving efficiencies in both passenger vehicles PV and EVs. Certified VMA-1 Value Engineer by SAVE and Six Sigma Green Belt. Strong interpersonal skills with a focus on time management and effective decision-making.
Overview
9
9
years of professional experience
2
2
Certifications
4
4
Languages
Work History
Senior Manager – Cost Engineering & Value Engineering
TATA Motors
01.2024 - Current
- Responsible for part-level target costing, preparation of detailed should-cost estimates, and implementation of cost control strategies to meet design-to-cost and source-to-cost objectives.
Led VAVE workshops, validated ideas, and drove cost reduction initiatives through competitive teardowns, benchmarking, and analytical levers.
Handled complete Powertrain aggregates for passenger vehicles (PV), IC & Electric vehicles (EV), including Engine, Transaxle, and Cooling system modules.
Created and managed budget allocations for new program, Cost Book accounting and engineering change notices (ECNs).
Partnered with procurement and engineering teams to achieve aggregate cost reduction targets.
Supported buyer negotiations with accurate cost insights and should-cost data.
Estimated costs for new technology parts, proprietary components, and both black box and gray box items.
Developed a knowledge repository for Powertrain components and subassemblies, incorporating competition insights, manufacturing processes, and technology benchmarks.
Product Cost Engineer – Global Sourcing & VAVE
Stellantis - HCLTech
07.2021 - 01.2024
- Developed detailed cost models for sourcing packages, CN/ECO/ECR concepts, and conducted cost gap analyses between supplier quotes and internal estimates.
Created and presented cost walks to supplier and buyer benches to support negotiation and commercial alignment.
Reviewed supplier offers and supported the Finance team by uploading final pricing into the CODEP system for fund approvals.
Drove teardown benchmarking, performed carbon footprint gap analysis, and led product-level BOB (Bill of Build) and material usage analysis.
Managed costing for Machining, Casting, Sheetmetal, Pipe Fabrication, and stamping components, including blank layout finalization.
Created executive dashboards on monthly savings, missed opportunities, and material cost avoidance for leadership reviews.
Submitted cost-saving and value-added idea reports, and regularly conducted weekly review sessions with client benches.
Cost Engineer – Should Costing
CARESOFT GLOBAL PVT. LTD.
01.2019 - 07.2021
- Defined cost targets and provided cost-effective solutions for commercial vehicles (trucks, buses, cars, construction equipment, harvesters).
Developed manufacturing processes, including operations, machines, labor, and cycle times for assemblies and systems.
Conducted should-cost analysis for materials like sheet metal, structural tubes, and machined components.
Led gearbox assembly costing and managed cost impact analysis during ECO processes.
Analyzed supplier quotes, aiding cost optimization and supporting supplier negotiations for target cost reductions.
Created costing templates to standardize evaluations for in-house manufacturing processes.
Optimized production costs by comparing cycle times, machine rates, and labor costs across different processes.
Estimated materials, equipment, and labor costs for specific manufacturing locations.
Technical Module Trainee
TVS Brakes India Pvt.Ltd
07.2016 - 12.2019
- Worked in Arvin Meritor Brake Assembly, contributing to NPD activities in machining and stamping.
Skilled in cost calculation for material, processes, secondary operations, and overhead for custom parts.
Expertise in calculating cycle times for sheet metal and machining parts based on material and machine tonnage.
Led machine setup, troubleshooting, and problem resolution for CNC lathe, VMC, HMC, and SPM machines.
Conducted tool pre-setting, tool changes, and machine offset corrections based on CMM reports.
Managed production cell documents for IATF audits.
Proficient with machines like DOOSAN DAWEOO, ACE, CINCINNATI, TAKISAWA, and MAZAK.
Operated CNC lathe, VMC, HMC, and various saw and tapping machines.
Education
Cost Management Accountant - Costing & Finance
04.2001 -
B. Tech - Mechanical Engineering
Diploma - Mechanical Engineering
04.2001 -
Senior Secondary (XII) - undefined
Higher Secondary (X) - undefined
Skills
Certification
Six Sigma Green Belt, Proven workshop report cost savings up to 105,000 USD in consumer appliance product.
Personal Information
- Passport Number: PO127209
- Driving License: Heavy Motor Vehicle
Accomplishments
- Decoded costs for blackbox technology.
- Conducted cost discovery for Porous ducts & Sodium filled Exhaust Valve.
- Achieved cost avoidance of INR 22 Cr.
Timeline
Senior Manager – Cost Engineering & Value Engineering - TATA Motors
01.2024 - Current
Product Cost Engineer – Global Sourcing & VAVE - Stellantis - HCLTech
07.2021 - 01.2024
Cost Engineer – Should Costing - CARESOFT GLOBAL PVT. LTD.
01.2019 - 07.2021
Technical Module Trainee - TVS Brakes India Pvt.Ltd
07.2016 - 12.2019
ICMAI - Cost Management Accountant, Costing & Finance
04.2001 -
Thevenesam Eruthayammal Polytechnic - Diploma, Mechanical Engineering
04.2001 -
Government Higher Secondary School - Senior Secondary (XII),
Government Higher Secondary School - Higher Secondary (X),
SRM Institute of Technology - B. Tech, Mechanical Engineering
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