Damodharan Iyamperumal

In my capacity as a Project Manager, I've led the implementation of the Digital Thread in Manufacturing Process Planning and supervised the establishment and upkeep of a 3D Factory (utilizing Scan to 3D Layout). I ensured the integration of CLL and Change content within the factory's simulation to align with Production Intent, focusing on identifying High Hurts and Lessons learned to prevent recurrence in future programs.

During my previous responsibilities in Trim and Chassis Assembly Line, I actively contributed to the launch of various new models such as Freestyle, Figo Aspire, Eco-sport, and Endeavor, thereby enhancing my value in my current role.

My expertise spans a range of tools including GSPAS (Siemens Easy Plan or MPP), Team Center (CAD), PRPO (Purchase Order), PFMEA & MFMEA, Cycle Line Layout, High Hurts, Lessons Learned, and Process Allocation techniques such as RTO, Kaizen, and Waste Elimination. I've also managed QOS Documentations like SPC (Control Charts), MSA, and utilized In-station Control Document Quality Tools like 6 Sigma, G8D, among others.

With a Diploma in Electrical and Electronic Engineering and over 19 years of experience in the Automotive industry, particularly focusing on Digital Thread initiatives, I possess a profound functional understanding of PLM (Tce / AWC), Connect Tools (NX - Siemens), Automotive Vehicle Assembly, and New Model Launch Coordination. I am currently seeking challenging career opportunities within the automotive sector.

• Accomplished the implementation of Easy Plan and AWC for two North American programs.
• Achieved successful deployment of Enhanced Dynamic Simulation.
• Conducted a successful pilot on the Connected Testing System for the final phase.
• Established successful connectivity between PLM and Plant Systems through API integration.
• Spearheaded a successful initiative resulting in a 70% reduction in Digital Thread issues by collaborating closely with IT and Siemens.

Lead Engineer (Project Manager) in Digital Engineering Factory, Manufacturing 4, from August 2018 to November 2021. Coordinated various plant statuses to transition to Digital 3D Assembly through the 3D Factory Creation Plan. Oversaw meetings regarding CLL and Change content for current and future programs to ensure updates in the 3D Factory and reduce implementation costs, faults, and installation timing by identifying errors earlier through simulation studies.

Accomplishments:

• Successfully completed 3D Factory for 2 AP Paint Shops and simulated Facility Change requirements in 3D.
• Studied and implemented 3D Factory creation and simulation for 11 FAE Assembly Shops (5 in Asia and 6 in North America) for future program expansion and implementation study.

Senior Engineer in New Model Launch Assembly Shop from September 2013 to August 2018. Coordinated various Proto and Trial build plans to achieve program targets within timelines. Managed craftsmanship build plans to achieve targets, and developed and implemented Final Chassis Area control plans. Identified, tracked, and resolved tooling, process, and design concerns encountered during builds.

Accomplishments:

• Achieved on-time delivery for Ok to Buy Score Card for Figo, Aspire, Europe Export, and Freestyle.
• Supported New Model Program in Australia for completing their build event on time (New Endeavour and Freestyle).
• Implemented Lean Material flow in the plant for part feeding to access more complexity.

End of Line & Repair Team Leader in Zone 6 from June 2010 to August 2013. Ensured scheduled production numbers were met with required quality, and all safety requirements and compliance were in place. Conducted regular review meetings to improve the health of the TCF shop in all aspects and ensured all training requirements were met. Reduced scrap cost, investment cost, and operating costs through VSM & Kaizen.

Accomplishments:

• Reduced manpower and station by 2 and 1 respectively through VSM Project.
• Decreased defects from 32% to 2% through G8D on Head Lamp wrong Focus.
• Received awards for Best Kaizen for the Year 2006(Q1) and 2007(Q2) and VSM in the Year 2009(Q3).

• Ford of Europe, Germany
• Ford of Australia