Karthikeyan
Automobile leadership professional
Changalpattu
Summary
With over 25 years of experience in manufacturing, quality, and product development, this dynamic automotive professional has a proven track record in successfully launching flagship electric and ICE vehicles for top OEMs such as Mahindra, Renault-Nissan, and Hyundai. Expertise lies in driving innovation and delivering exceptional results in the automotive industry.
Overview
25
25
years of professional experience
8
8
years of post-secondary education
4
4
Languages
Work History
Deputy General Manager - Proto BIW & Vehicle Manufacturing
Mahindra & Mahindra Ltd
08.2011 - Current
- Electric Vehicle Build New Vehicle issue resolutions
- Expertise in BIW build & Vehicle build Product development
- Heading the Proto BIW & Vehicle manufacturing shop & managing a diverse team of 400 associates and 35 engineers, which resulted in the successful production of initial batch vehicles and ensured timely project deliveries in alignment with masterplan requirements
- This strategic oversight created a seamless workflow that enhanced efficiency and quality in vehicle assembly operations, leading to minimized defects per unit
- Developed in-house BIW fixtures and assembly process sheets, along with training for technicians and operators, which ensured that assembly activities were executed with precision and quality adherence
- This proactive training approach cultivated a skilled workforce capable of meeting quality standards with reduced defect rates
- Conducted thorough inspections and audits of finished vehicles & BIWs employing GNOVAC & GNOVAB audits to ensure product robustness prior to testing
- As a result, the vehicles not only met but exceeded quality expectations, greatly enhancing customer satisfaction and market reputation
- Resolved complex field issues for customers by traveling across India, which facilitated immediate technical support and problem-solving during mass production ramp-up phases
- This hands-on involvement stabilized production lines and ensured smooth vehicle rollout, thus improving overall operational reliability
- Spearheaded the rapid development of groundbreaking Electric Vehicles BE 6E & XUV 9E, from concept to launch within an ambitious three-year timeline, setting new industry benchmarks for features and performance
- The successful launch not only attracted significant media attention but also positioned these vehicles as frontrunners in the competitive EV market, resulting in notable consumer interest and sales
Assistant Manager - Vehicle Quality Assurance
Renault Nissan Automotive India Pvt ltd
07.2010 - 08.2011
- Managed shop floor operations in the Vehicle Assembly End of Line Quality Assurance Department, resulting in increased efficiency and adherence to quality standards across multiple inspection lines
- Led the implementation of the Nissan Vehicle Evaluation System (VES) and AVES, which significantly enhanced the accuracy of vehicle audits and improved customer satisfaction
- Conducted daily process and product audits, publishing quality results and facilitating meetings with stakeholders, which promoted accountability and fostered communication to drive quality improvements
- Chaired QRQC meetings with cross-functional teams to target vehicle quality goals and address chronic issues, leading to a measurable reduction in defects and improved production timelines
- Regularly audited the shop floor for compliance with 5S, safety, and Genba Kandri requirements, ensuring a well-maintained and safe work environment that boosts overall operational productivity
Assistant Manager - Vehicle Assembly Quality Control
Hyundai Motor India Ltd
02.2006 - 07.2010
- Ensured the quality of finished vehicles at the Assembly shop's end-of-line inspection to enhance customer satisfaction and reduce defect rates
- Conducted daily meetings with cross-functional teams to address quality issues and implement countermeasures, leading to improved collaboration and quicker resolutions
- Performed durability trials on new vehicle models prior to market introduction, resulting in higher reliability and customer trust in new products
- Analyzed part failures using the 8D problem-solving approach, identifying root causes and recommending solutions to reduce recurrence and enhance product quality
- Monitored field complaints and coordinated efforts to pinpoint issues and assign responsibilities, ensuring effective countermeasures were implemented within target timelines to maintain product integrity
Assistant Works Manager
Sundaram Motors ltd
06.2004 - 01.2006
- Oversaw service operations for GM cars at Sundaram Motors, managing a team of four supervisors and 40 technicians while enhancing operational efficiency and service quality
- Conducted daily reviews of customer complaints through meetings to proactively identify and address service quality issues
- Implemented technical training programs for technicians and supervisors that resulted in improved service skills and customer satisfaction
- Allocated technician assignments based on individual skills and vehicle requirements to maximize productivity and ensure effective service delivery
- Developed and maintained quality assurance protocols which led to a significant reduction in service errors and increased customer trust
Workshop Supervisor
V.S.T.Motors Limited
07.2000 - 05.2004
- In-charge of service operations of Tata passenger cars in V.S.T.Motors with 2 Supervisors and 23 Technicians
- Reviewing the customer complaints on daily basis through meetings to ensure the quality
- Conducting technical trainings for technicians and supervisors to improve quality service
- Allocating jobs to every technician according to their skills and vehicle reporting
Education
Master Of Engineering - Manufacturing Engineering
Vinayaka Mission University
09.2006 - 06.2008
B.Tech - Mechanical Engineering
Vellore Institute Of Technology
09.2001 - 05.2005
Diploma In Mechanical Engineering - Mechanical Engineering
Swamy Abedhanandha Polytechnic
06.1997 - 04.2000
Skills
- EV Expertise
- EV Manufacturing expertise
- EV diagnostic expertise
- Vehicle manufacturing expertise
- Vehicle quality
- BIW Quality
- BIW manufacturing
- Buck & mule development expertise
- Vehicle testing expertise
- Vehicle validation
- Expert ride & handling subjective evaluation expertise
- Vehicle level jury evaluation expertise
- Vehicle project management
Extra-Curricular Activities
District level winner in Volleyball, 07/01/96 - 04/01/97
Publications
- Drag Reduction In Electric Vehicles, SAE international, 09/27/15
- Reduction of Electric vehicle power consumption through design optimization of front axle unitised bearing R W S, 03/30/19
Preferences
- Manufacturing
- Product development
- Quality assurance / control
- Project management
- Vehicle testing & validation
Timeline
Deputy General Manager - Proto BIW & Vehicle Manufacturing
Mahindra & Mahindra Ltd
08.2011 - Current
Assistant Manager - Vehicle Quality Assurance
Renault Nissan Automotive India Pvt ltd
07.2010 - 08.2011
Master Of Engineering - Manufacturing Engineering
Vinayaka Mission University
09.2006 - 06.2008
Assistant Manager - Vehicle Assembly Quality Control
Hyundai Motor India Ltd
02.2006 - 07.2010
Assistant Works Manager
Sundaram Motors ltd
06.2004 - 01.2006
B.Tech - Mechanical Engineering
Vellore Institute Of Technology
09.2001 - 05.2005
Workshop Supervisor
V.S.T.Motors Limited
07.2000 - 05.2004
Diploma In Mechanical Engineering - Mechanical Engineering
Swamy Abedhanandha Polytechnic
06.1997 - 04.2000
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