Chandhan H S

Product: TATA SIERRA.

My contribution directly strengthened Tata Group's product development efficiency, manufacturing readiness, and customer satisfaction in the following ways.

1. Improved vehicle quality and BSR performance.

By developing accurate fixtures and executing detailed GD&T, gap, and flush studies. I helped the organization significantly reduce BSR issues, leading to improved cabin refinement, and enhanced customer perception of quality.

2. Accelerated Vehicle Development Cycles.

My early Class-A to S1 surface development, combined with robust DFM, DFA, and DFS integration, reduced downstream engineering rework and ensured faster design sign-offs, saving critical lead time in concept-to-production cycles.

3. Enhanced Dimensional Robustness and Manufacturing Feasibility.

Through complete tolerance stack-up studies and rigorous CTQ identification, I ensured that BIW and interior components were manufacturing-friendly, reduced tool rework, scrap, and assembly line issues.

4. Strengthened cross-functional collaboration and execution discipline.

Weekly project tracking, MoMs, closure reports, and coordination with Tata Design Studio, manufacturing teams, and suppliers helped maintain delivery discipline and improved organizational efficiency.

5. Cost Optimization and Process Efficiency.

By evaluating BIW joinery feasibility, materials usage, and mold/tolling strategies. I have contributed to lowering costs, improving yield, and achieving the company’s cost targets without compromising functionality.

6. Improved Prototype Maturity and Production Readiness.

Hands-on involvement in prototyping development and post-mass production verification ensured that the project transitioned smoothly from engineering intent to manufacturable and service-ready components.

Product: INDIAN ARMY EV VEHICLE(4 & 2 WHEELER).

• Planned and designed battery pack jigs for complete assembly, including fixtures for sorting (IR testing) and grading (voltage grading), and integrated new battery pack modules with the existing line for the dry line.
• Conducted line studies, ergonomic studies, and reach studies for battery module pick-and-place grippers, and adhesive dispensing grippers.
  Designed cell tube assemblies for 21700, prismatic cells, and Molicell.
• Led chassis design and manufacturing for a two-wheeler prototype.
• Developed containers and battery packs with 4 MW capacity, including racks, frames, and module placements.
• Implemented poka-yoke (error-proofing) in the battery assembly line, and designed sheet metal components.
• Built a semi-automated line from station 10 to 60 for battery laser bonding and module fixtures to achieve a transition from manual to automated module movement.
• Authored SOPs, PFMEA, DFA, DFMEA, validation reports, and conducted cycle time and root cause analysis.
• Planned assembly processes and layouts, integrated robots with GRACO dispensers, and developed control plans.
• Managed design releases, manufacturing feedback, costing, and quality control, and oversaw tool trials and improvements.
• Supervised underbody and upper body assembly, pre-production fixtures, and 3D printing for prototype validation.
  Implemented lean process planning and improvements, focusing on cost reduction and waste elimination (TIMWOOD, MUDA).
• Conducted process and tool validation, and developed process flow charts; oversaw milling, bending, and laser bonding machines.

• Designed and validated fixtures for floor panels as per ALTINAY standards, rear body fixtures per BMW standards, and detailed Geo stations for underbody assembly according to Bentley standards.
• Developed roof and turntable assemblies for body sides as per AMG standards, and created 3D concepts, finishes, and 2D detailing for rudders and vertical stabilizers per TROYA Brasil standards.
• Designed spot welding fixtures for body side assemblies following GM standards, and underbody fixtures in line with TESLA standards.

• Designed complete assembly lines for semi-truck underbodies for the U.S. market, and developed design process plans to streamline workflows.
• Engineered GEO stations, respot stations, grippers, pass tables, turntables, pallet conveyors, gun stands, and docking stands.
• Validated standard components and designed framinDesigned complete assembly lines for semi-trucks underbody for the US market and developed
  design process plans to streamline workflows.
  Engineered GEO stations, respot stations, grippers, pass tables, turntables, pallet conveyors, gun
  stands, and docking stands.
  Validated standard components and designed framing lines to enhance structural integrity and
  assembly efficiency.g lines to enhance structural integrity and
  assembly efficiency.

• Designed BIW fixtures for the Thailand and Australia markets, and sunroof and moonroof fixture stations for the US market.
• Created underbody and upper body fixtures for the New Zealand market, and fixtures for rear close-out BIW and body side assemblies.
• Planned design processes for various projects, and validated standard components for fixture designs.