Chandra Mani
Pune
Summary
A vigilant, meticulous, and competent individual with over 10+ years of captivating experience in Automotive & Li-Ion cell and Battery Industries with emphasis on Operations, Manufacturing Engineering, and General Management. Seeking to pursue a career in the upper echelons of an esteemed organization, that calls for extremely high levels of technical abilities and regulatory knowledge and expertise, with the goal of steering plant operations and process excellence in the manufacturing environment to enhance the company's productivity and profitability.
Overview
12
12
years of professional experience
4
4
Certificates
2
2
Language
4
4
years of post-secondary education
Work History
Manager (Li-Ion Battery Manufacturing)
Mahindra Electric Mobility Ltd
Pune
09.2023 - Current
- Spearheading the development and implementation of world-class manufacturing operations strategies, policies, and procedures that are aligned with the company's mission and vision
- Implementing lean manufacturing principles, including process mapping, waste reduction, and continuous improvement initiatives, to drive efficiency, reduce costs, and improve quality
- Steering the development and implementation of effective policies and procedures, monitoring key performance indicators (Safety, People, Quality, Production and Cost KPI), and driving continuous improvement initiatives to optimize performance and achieve business objectives
- Develop and manage annual budgets and production targets, analyzing cost reports, labor metrics, and Overall Equipment Effectiveness trends
- Drive production goals, KPIs, and key initiatives, collaborating with cross-functional teams to resolve bottlenecks and enhance productivity
- Developed and implemented advanced manufacturing processes for lithium-ion battery production, resulting in a 25% improvement in energy density and a 30% reduction in manufacturing costs
- Manage equipment suppliers and internal design team through development and deployment milestone PO release, FAT, FDR, SAT, SOP and Ramp up
- Spearheading manufacturing of XUV400 EV battery pack (Variants - 350V, 39.35Kwh, 34.5kwh)
- Identifying bottlenecks & hindrances for enhancing productivity, finding solutions, and streamlining production
- Development for Battery Pack & validation
- Knowledge of Standards / procedures / check sheets / previous project data & results for each type of activity
- Examine inputs, understand Customer requirement, and generate queries if required
- Conversant with handling sophisticated Cell, Module, Pack Sub-Assembly Line, and their Testing equipment (IR testing, C Rate Testing, CAN communication testing, Air leakage, Cell voltages limits & SOCs)
- Co-ordinating with R&D team in Prototyping along with BOM review
- Conducting the CFT Approach for resolving the issues in EOL/Charging like Cell max- min voltage, temperature issue, BDU, HPPC abort, Capacity Loss, fuse out, wiring harness issue related to pack, BMS and BMU issue, SOC parameter limits
- Analyzing customer’s complaints and implementing appropriate corrective & preventive actions along with 8D analysis with process enhancement
- Working on out different software like Vehicle SPY, ESD, TAP developed by Keysight for battery testing, analyzing the data with DTC code & CAN data with CANoe Analyzer
- Responsible for production including daily production planning, delivery to plan, production cost, (FTT) first time yield, safety, quality targets, and production staffing
- Conducted root cause analysis for quality deviations, implemented corrective actions, and improved first-pass yield by 18%
- Designed and implemented manufacturing processes for lithium-ion cell & battery assembly, ensuring compliance with industry standards and safety regulations
- Collaborated with R&D teams to introduce new materials and technologies, resulting in a 30% improvement in energy density
- Led the scale-up of production lines, increasing capacity by 40% to meet growing market demands
- Foster a strong safety culture, collaborating across the organization to meet or exceed all PSM and OSHA standards
- Ensure plant operations and facilities adhere to safety protocols, implementing necessary measures to enhance workplace safety
- Lead initiatives for continuous improvement, engaging all levels of the team in impactful improvement ideas and projects
- Implement lean principles, theory of constraints, and material flow improvements to enhance overall efficiency.
Deputy Manager (Manufacturing Engineering, Li-Ion Cell & Battery Production)
Exide Energy
Bengaluru
02.2023 - 08.2023
- Worked as Deputy Manager manufacturing engineering, responsible for the entire gamut of plant operations, including manufacturing, manufacturing engineering, planning & control, procurement/purchase, and supply chain management to ensure that the operating goals and objectives of the organization are met, in accordance with SOP of Jan 2024
- Designed and implemented scalable manufacturing processes for lithium-ion battery components, including electrode materials, separators, and electrolytes
- Worked as a Green field project leader, leading activities -for manufacturing equipment process for high voltage battery packs (138KWh, 198KWh & 260KWh) used in Electric Buses
- Played a key role in the development and testing of new battery technologies, resulting in the successful launch of a high-performance product line
- Developed process flow, PFMEA & MFMEA for cylindrical battery assembly (138KWh, 198KWh & 260KWh)
- Collaborated with R&D teams to transfer laboratory-scale processes to full-scale production, ensuring seamless integration and efficient scale-up
- Implemented Lean Manufacturing principles, leading to a 20% reduction in production cycle time and a 15% improvement in overall equipment efficiency
- Successfully installed and commissioned 250 MWh proto-Line for cell assembly (21700) in a record time of 120 days
- Rolled out first batch of 21700 cells in June 2023
- Lead the project for equipment concept design, 3D design evaluation and manufacturing of equipment for Prismatic (105AH, 226Ah, 257Ah) and cylindrical cell (21700 and 66180) manufacturing
- Planning, scheduling & implementing plant capacity enhancement activities, implementation of SOP, quality & safety guidelines
- Responsible for co-ordination with OEMs in the design of manufacturing equipment, process, and tooling for battery pack assembly line
- Following change management whenever there is a process change and for process improvement.
Asst Manager (Cell Manufacturing, Li-ion Cell & Battery Formation)
TDS Lithium-Ion Battery Gujarat Pvt Ltd
Ahmedabad
10.2018 - 03.2023
- Successfully launched India’s first green field project for li-ion cell manufacturing plant construction sites with a total investment of 250 million USD, by developing tools, processes, and installing and proving out cell manufacturing and assembly production lines, within 18 months of project launch
- Spearheaded process optimization initiatives resulting in a 15% increase in production efficiency and a 20% reduction in manufacturing costs
- Developed and implemented standardized operating procedures (SOPs) to ensure consistent and high-quality lithium-ion cell production
- Collaborated with cross-functional teams to troubleshoot and resolve production issues, leading to a 25% decrease in downtime
- Coordinated with other departments to ensure that production schedules are met, equipment’s are repaired, when necessary, materials are available when needed, and labor costs are monitored
- Developed Dry-room Requirements, Machine Layout Planning, Installation, Commissioning and Experiments-trials for cell manufacturing
- Developed Machine and Process Design Parameters for effective cell manufacturing
- Established Technical Standards-PFMEA, CP & Check sheets for Cell Manufacturing
- Through Knowledge on manufacturing process prismatic lithium-ion cells, cell and battery formation, cell assembly, winding and stacking
- Achieved significant improvement in First Time Through (FTT) in Final Assembly from 90% to 98%, which reflects the team's commitment to operational excellence and continuous improvement
- Drove productivity improvements by instilling a Continuous Improvement (CI) mindset across the organization and providing effective coaching on lean methodologies
- Spearheaded the complete manufacturing engineering and operations management (Safety, Quality, Delivery, Cost, and People) of cell formation unit
- Coordinated with other departments to ensure that production schedules are met, equipment’s are repaired, when necessary, materials are available when needed, and labor costs are monitored
- Analyzing data to identify opportunities for improving productivity, reducing costs, increasing revenue, or preventing accidents
- Responsible for management of the process of new machinery, plant, and equipment from drawing up the specification and managing supplier through to full installation and commissioning in collaboration with interested parties
- Through Knowledge on manufacturing process of cylindrical (21700) and prismatic lithium-ion cells, cell and battery formation, cell assembly, winding and stacking
- Prepare assembly and process specifications, along with other engineering documents
- Responsible for process validation, improvement, and process design modification
- Define Cycle time / OEE and other performance target with industrial engineering to develop optimal operating and labor strategies
- Lead simultaneous engineering with product, purchasing and suppliers to deliver manufacturing feasibility
- Drive design for manufacturability for new Cell and Module products
- Responsible for co-ordination with OEMs in the design of manufacturing equipment, process, and tooling
- Following change management whenever there is a process change and for process improvement
- Responsibly lead team of engineer and technician in development of 6Ah high power prismatic SCIB Li-ion cell
- Have extensive knowledge of operation and maintenance of equipment’s for Electrode manufacturing, Cell Assy, Ultrasonic Welding, Winding Machine, Electrolyte injection machine, Laser welding, Degassing, Charge-Discharge equipment, vision applications, Pneumatics and all other related equipment’s of Li cell assembly, Battery Assembly equipment, Battery Formation and Testing equipment, clean and dry room
- Responsible for integration of process control parameters into manufacturing process
- Maintaining Production data, OEE, yield rate, skill mapping &Breakdown, Kaizen, and Improvement as per company standards
- Troubleshooting and analysis using FTA, DMAIC, RCA approach and data analysis using SPOTFIRE and Mini-Tab
- Capable of handling LI-ion battery characteristic monitoring system, Vision monitoring system of Keyence.
Maintenance Engineer (Assembly, Formation, and Extrusion)
Cooper Standard
Ahmedabad
07.2015 - 10.2018
- Maintenance Engineer (Assembly, formation, and extrusion) at Cooper Standard in Ahmedabad from July 2015 to Oct 2018.
- Performed troubleshooting and repair for complex electrical equipment
- Investigated and corrected mechanical problems with machinery
- Dismantled defective machines and equipment and installed new or repaired parts
- Organized and directed maintenance shutdowns and startups
- Completed partial or full dismantling of equipment to quickly repair or replace defective components and restore functionality
- Diagnosed and resolved machine operation variations and equipment problems
- Worked frequently with mechanical and plumbing systems to complete knowledgeable inspections and skilled repairs
- Visually inspected and tested machinery and equipment, performing routine preventive maintenance
- Cleaned and lubricated parts to keep equipment operating at peak performance
- Reviewed technical documentation to complete equipment maintenance and repair
- Documented maintenance activities and confirmed compliance with relevant regulations
- Trained and supervised staff on equipment maintenance and safety procedures
- Developed preventive maintenance schedules to minimize downtime and optimize performance
- Diagnosed and repaired complex mechanical and electrical systems
- Performed preventive maintenance and repairs on various types of equipment
- Detected and repaired machinery faults using electrical and manual testing methods
- Supervised maintenance functions, working collaboratively with sanitation crews on shop floor upkeep and repairs
- Optimized work readiness with effective gathering of parts and supplies in alignment with specifications
- Replaced worn or broken parts on machines and equipment
- Continuously adhered to strict regulations as well as detailed instructions, guidelines and specifications
Maintenance Engineer (Wire and Wiring Harness)
VI-SON WIRE PVT LTD
Vapi
07.2014 - 06.2015
- Maintenance Engineer (Wire and wiring harness) at VI-SON WIRE PVT LTD in Vapi from July 2014 to June 2015.
Maintenance GET (Wire and Wiring Harness)
MSSL
Noida
05.2010 - 10.2011
- Maintenance GET (Wire and wiring harness) at MSSL in Noida from May 2010 to Oct 2011.
Education
M.Tech -
VNIT, Nagpur
Nagpur 01.2024 - Current
B. TECH - Electrical And Electronics Engineering
GOKUL INSTITUTE OF TECHNOLOGY & SCIENCES
Vishakapatnam India 08.2006 - 09.2010
Skills
Plant operationsOperation ManagementContinuous ImprovementProcess EngineeringTeam ManagementNew Product Launches (Green & Brown fields Projects) Projects)TPMProject Management
Teamwork and Collaboration
Organization and Time Management
Analytical and Critical Thinking
Multitasking Abilities
Quality Assurance
Decision-Making
Certification
Certified IATF Auditor.
Timeline
M.Tech -
VNIT, Nagpur
01.2024 - Current
Manager (Li-Ion Battery Manufacturing)
Mahindra Electric Mobility Ltd
09.2023 - Current
Deputy Manager (Manufacturing Engineering, Li-Ion Cell & Battery Production)
Exide Energy
02.2023 - 08.2023
Asst Manager (Cell Manufacturing, Li-ion Cell & Battery Formation)
TDS Lithium-Ion Battery Gujarat Pvt Ltd
10.2018 - 03.2023
Maintenance Engineer (Assembly, Formation, and Extrusion)
Cooper Standard
07.2015 - 10.2018
Maintenance Engineer (Wire and Wiring Harness)
VI-SON WIRE PVT LTD
07.2014 - 06.2015
Maintenance GET (Wire and Wiring Harness)
MSSL
05.2010 - 10.2011
B. TECH - Electrical And Electronics Engineering
GOKUL INSTITUTE OF TECHNOLOGY & SCIENCES
08.2006 - 09.2010
Knowledge Purview
Offering Profound knowledge and experience in Operations, Manufacturing Engineering, and General Management in Automotive & Li-ion cell & battery Industries.
Exhibited unparalleled technical prowess in Production, Manufacturing Engineering, Maintenance, & New Product Launches both in Green and Brown fields.
Advanced knowledge of Li-cell manufacturing and process improvement methodology (Kaizen, 5S, Six Sigma & Lean Manufacturing, etc.).
In depth experience in Lean Manufacturing of Suzuki Motor Company’s Manufacturing Engineering /Lean Manufacturing /Quality System (Suzuki production System), by virtue of direct involvement in its implementation and day-to-day execution in real time production environment.
Adroit at maintaining current knowledge of Manufacturing Engineering new technologies and processes through undergoing in-housetraining programs, interacting with industry professionals, and attending certification courses from reputed institutes to understand the industry trends and bring back the best practices to the organization.
Attributes
- Innate Problem-solver
- Unwavering Professionalism
- Resilience and Persistence
- Intellectual Curiosity