Ezhilarasan Murukesan

"Spearheaded multiple high-profile projects, delivering exceptional results in:

- On-site installation and delivery of the HV Battery program in South Africa in IMG market Group.

- Global I4 engine program study, brownfield engineering, and delivery

- EV BEV/PHEV Battery test strategy and programming.

Key accomplishments:

- Prepared detailed scope work documents for RFQ EV battery/engine assembly and test

- Identified and evaluated potential suppliers for program requirements

- Engineered and delivered battery test machines for proto and manufacturing facilities

- Optimized layout for assembly test equipment.

- Process sheet, Dynamic contorl plan, PFMEA,Control plan,Global standrads adhereance,Error proof matrix, Risk assessment, MBOM, MFMEA, Test strategy, line balancing.

- Digital tools Virutual build, Process and Fesibility study.

- Teamcener,vismockup 3D, autocad 2D.

- Led design and implementation of battery test wiring harness

- "Successfully engineered and validated a Proof of Concept (POC) for battery leak testing, with a proven solution deployed on-site, demonstrating effective problem-solving and innovation in ensuring battery quality and reliability."

- Developed battery test strategy response for new HV Battery program

- Engineered battery electric test and leak test programs

- Conducted HV Battery assembly and test engineering study

Proven expertise in leading cross-functional teams, driving innovation, and delivering results-driven solutions in the automotive industry, particularly in EV battery and engine assembly, test, and manufacturing."

-led engineering and installation activity to deliver V6 engine test facility to South Africa- international market group in 2020-2022.

-Engineering, virtual run-off, installtion of engine assembly test equipments.[ Torque to turn station, leak test station, cold test, hot test, Dyno, Cylinder Head assembly].

-3D modeling and simulation to validate the equipment design.

- validating the equipment control system , pneumatic, fluid system circuits to meet the requirements part of standards.

-Implementation of RBM programing for assembly line.

- Retooling of I4,I5 engine setup line to add V6 without seeing facility and engine model.

- led test strategy finalization and cost study.

-led engineering activity to deliver I4 IC engine test facility to Sanand engine plant in 2019-2020.

- Developed new test harness vendor.

- Design of wiring harness by using additive manufacturing technology [3D print], implemented as proto and successfully implemented to IC engine and battery test equipments.

-2017 SixSigma Green belt certification- Process and cycle time provement.

-led installation activity to deliver I4 IC BS6 engine test facility to Sanand plant in 2017 -2018.

- Implemented and validated I4 engine test equipments. skilled in Cold test and dyno test station.

- New engine PV test setup, facility readiness, programing and validation.

*Leadership in Automotive Manufacturing*

- Led Greenfield project for 500cc BMW vehicle and engine assembly facility readiness

- Spearheaded assembly automation initiatives

- Pioneered virtual input/output diagnostic IIOT in engine assembly automation line

- Championed low-cost solution automations, ensuring efficiency and cost-effectiveness

- Directed shift operations, addressing day-to-day assembly, machining, and painting issues

- Conducted root cause analysis using "why-why" methodology to implement corrective actions

- Led breakdown maintenance team of 20 for two-wheeler line

- Drove TPM (Total Productive Maintenance) initiatives, focusing on CBM (Condition-Based Maintenance) and TBM (Time-Based Maintenance)

- Oversaw control logic machine upgrades to PLC (Programmable Logic Controller)

- Supervised plant maintenance for two-wheeler machining, engine, vehicle assembly, and painting equipment, leading a team of 45

*Key Skills:*

- Automotive manufacturing leadership

- Assembly automation and IIOT implementation

- Root cause analysis and problem-solving

- TPM and maintenance strategy development

- Team management and supervision

- Cost-effective solution implementation

- PLC and control logic management

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