Summary
Overview
Work History
Education
Skills
Certification
LANGUAGES KNOWN
Accomplishments
Awards
Patent Applied
Timeline
Generic
Jayaprakash Kamaraj

Jayaprakash Kamaraj

Bangalore

Summary

Action-oriented management individual with expertise in EV vehicle module design and development and EV component validation, cross-functional team leadership & delivering positive results with strong and sustainable profits. Able to identify the right suppliers and implement strategies to reduce costs, increase sales, strengthen customer relationships, improve business practices and drive profitable growth. Broad-based management skills with strong planning, communication, team building, supplier development, organization and decision-making skills to successfully manage concurrent projects.

Overview

9
9
years of professional experience
1
1
Certification

Work History

EV 2W&3W OEM NPD AGM- Engineering

GREAVES COTTON LIMITED
05.2024 - Current
  • Full ownership of EV powertrain product design, development, and validation for L3, L5, N1, and HCV commercial vehicles across PAN-India.
  • Led market research and benchmarking for L3 and L5 automotive powertrain solutions; developed QFD matrices to design robust, customer-centric products tailored to both B2B and B2C requirements.
  • Expanded EV Powertrain business across India, acquiring 45+ customers and achieving 10,000+ units/month production volume with premium quality and cost competitiveness.
  • Pioneered localization of motors & MCUs and introduced rare-earth-free magnet designs, reducing supplier dependency, enhancing product quality, and improving long-term profitability.
  • Defined and executed product roadmaps, strategy, and vision, ensuring continuous improvement and alignment with customer and market requirements.
  • Designed, developed, and validated LFP & Li-ion batteries for L3 and L5 EVs, achieving optimized performance, safety, and cost efficiency.
  • Utilized Maxwell Motor-CAD, Simulink, and performance modeling tools for system-level design and optimization of PMSM, BLDC Hub, and Mid-Drive Motor Systems.
  • Engineered hardware integration packages including motor controllers, dashboards, BMS, PCNs, and battery enclosures for EV platforms.
  • Delivered technical presentations, RFQ/SOR responses, and prototype samples to customers, enabling successful evaluations and approvals.
  • Created detailed engineering drawings (child parts, sub-assemblies, end products, vehicle-level mounting) per GD&T standards using CATIA, Pro-E/AutoCAD, and ANSYS; performed tolerance stack-up analysis to ensure fit, form, and function.
  • Executed Model-Based Development (MBD) for automotive PTC components, covering MIL, PIL, SIL, and HIL modelling, simulation, and validation.
  • Led system simulation, calibration, integration, and testing for EV powertrain components within SIL & HIL environments.
  • Applied Functional Safety (ISO 26262) principles, including PFD creation, model integration, and optimization, ensuring compliance with industry safety standards.
  • Products offered, including setting product lifecycle strategy and ensuring execution to the defined plan of record for each product.
  • Facilitate review of market, technology, and competitive trends leading to development and revision of product strategy/roadmap and organizational priorities.
  • Functions as a central resource with design, manufacturing, quality, test, marketing, and distribution as the product(s) move through their lifecycle.
  • E-Power Train, Li, LFP, for L3 and L5 – Key Roles & Responsibility

NPD - Manager Engineering

ATHER ENERGY PVT LTD
05.2022 - Current
  • Designed, developed, and evaluated 3.6kW, 2.6kW, and 2kW PMSM & IPM motors for high-performance 2W applications tailored to Indian road conditions, ensuring high durability, reliability, and a lifecycle of 1.5 lakh km for 5 years.
  • Proficient in Maxwell Motor-CAD and Simulink for performance calculations, sizing, and system-level optimization of EV motors, including BLDC hub, Mid-drive, PMSM, IPM, SRM motor systems.
  • Expert in creating DV&P&R (Design Validation Plan & Report) test plans to meet product lifecycle requirements, applying various standards to ensure safety, functionality, performance, reliability, endurance, and durability at component, subsystem, and vehicle levels under real-world field conditions.
  • Developed and validated 60A, 70A, and 80A BMS-based motor controllers with speed- and torque-based control strategies for high-power 2W applications, built on scalable architectures with innovative technologies and optimized thermal efficiency.
  • Designed, developed, and evaluated 3.6kW, 2.6kW, and 2kW Li-ion & LFP battery packs for high-performance 2W applications optimized for Indian environmental conditions, delivering high durability, reliability, and lifecycle performance of 30,000 km or 5 years.
  • Developed and tested 60A, 70A, and 80A BMS modules (2kW) with advanced smart, CAN-based intelligent software for battery monitoring, active balancing, and safety management in 2W applications. Optimized for Indian environmental conditions, ensuring high durability, reliability, and lifecycle performance of 30,000 km or 5 years.
  • Expert in eliminating potential failure modes during the design phase for powertrain products including BLDC, PMSM, and EMS modules (motors, motor controllers, dashboards, batteries, and BMS). Strengthened supplier capacity and capability through systematic approaches to meet high-volume production requirements while ensuring quality and reliability.
  • Domain expert in end-to-end EV module development, from Gerber file to physical product, incorporating comprehensive electrical testing including ICT, FCT, X-Ray, and EOL, while ensuring compliance with design and process parameters.
  • Strong knowledge of PTC and EV model material selection, including stator, rotor, aluminium covers (front and back), shafts, wires, Phase, Sensors cables, hardware architecture, and PCBA, with expertise in component, sub-assembly, and end-product integration and associated process checkpoints.
  • EV Powertrain & EMS Engineering - Roles & Responsibility

EV Motor Design & Development SPECIALIST

SONA COMSTAR AUTOMOTIVE TECHNOLOGIES INDIA PVT LTD
07.2022 - 05.2022
  • EV Powertrain & Electronics Development Expertise
  • Design & Development: Responsible for end-to-end design, development, and validation of EV Hub Motors, Motor Controllers, BSG Systems, BLDC Traction Motors, and Starter Motors.
  • Electromechanical Systems: Hands-on experience in magnet design, mold development, stator, rotor, shaft, and winding optimization for EV, BSG, alternator rotors, and starter applications.
  • Roles & Responsibility

Team Lead R&D Specialist

HANON AUTOMOTIVE SYSTEMS INDIA Pvt Ltd
10.2018 - 07.2018
  • Design & Development Leadership: Responsible for end-to-end design and development of engine cooling systems for ICE and EV applications, ensuring functionality, durability, serviceability, and cost-effectiveness.
  • Thermal Calculations & System Sizing: Strong experience in thermal load calculation, system sizing, and performance prediction for engine and motor cooling modules.
  • Simulation & Modelling: Hands-on expertise in 1D simulation tools (KULI, Dymola) for system modelling and optimization; proficient in correlating simulation models with actual test results for validation and continuous improvement.
  • Cooling Module Design: Expertise in engine cooling module architecture, radiator design, refrigerant-based cooling system development for EV motors, and component packaging in line with vehicle-level requirements.
  • Advanced Technology Integration: Implemented innovative cooling technologies for size optimization, efficiency improvement, and enhanced thermal management of EV motors under varying operating conditions.
  • CFD & Structural Analysis: Organized CFD studies to analyse vehicle front-end airflow, grill opening requirements, and styling constraints; coordinated with CAE teams for structural validation of cooling systems.
  • Prototyping & Testing: Directed prototype builds, validation tests, RWUP procedures, instrumentation setup, and calibration activities at both component and vehicle levels.
  • Engine Cooling & Thermal Management Expertise: Unique Roles & Responsibility

Senior R&D Specialist

MAGNETIC MARELLI India Pvt Ltd
06.2016 - 09.2016
  • End-to-End Program Ownership: Lead for HVAC, Engine Cooling Module (ECM), Climate Control Module (CCM), and Auto Control Systems—covering design, development, validation, and PPAP launch from concept drawings to mass production.
  • Thermal & Functional Safety: Skilled in thermal load calculation, system sizing, and functional safety assessment to ensure design reliability and compliance with customer requirements.
  • Systems & Components Expertise: Strong technical knowledge of climate control systems, auto control logic, HVAC, ECM, BCM, and machine-level thermals, including EMI/EMC compliance and hardware reviews.
  • Electronics & Module Development: Proven track record in electrical/electronic product development, including CCMs, BCMs, compressors, switches, auto-control modules, and SCMs, with component selection, DFMEA, RCA/RSA, and CAPA leadership.
  • Vehicle Integration: Hands-on experience in integration and validation of engine mounting components (PTC heaters, ECM, AC hoses, BCM parts) at vehicle and subsystem levels for HV and BEV platforms.
  • System Modelling & Validation: Expertise in modelling and testing HV/PHEV system capabilities against DFMEA deliverables; skilled in refining and reviewing vehicle-level system architecture for multiple platforms.
  • Cross-Functional Collaboration: Liaised with design, thermal, electrical, and validation teams to achieve successful customer requirement compliance at the vehicle level.
  • Quality & Functional Safety: Support DFMEA, functional safety activities, and hardware technical support for system-level testing, including risk analysis, risk assessment, and contingency planning for critical products.
  • Requirements & Issue Resolution: Experienced in requirement engineering, system-level verification, and cross-functional issue resolution using Global 8D methodology, driving robust corrective actions.
  • Program Delivery: Ensure robust timing plans are executed to achieve key program milestones and targets across quality, cost, functionality, weight, and timing, with hands-on exposure to complex high-voltage systems (BEV, MHEV, PHEV).
  • Supplier Development & Guidance: Lead suppliers through the electronics design and validation phase, ensuring compliance with CK design and test specifications via Guidelines Review and Development of Electronics (GRADE) methodology.
  • APQP & Product Development: Strong knowledge of APQP methodology for part development, including drawing reviews, manufacturing feasibility studies, process capability assessment, and regulatory compliance for BEV/PHEV solutions.
  • Technical Documentation & Validation: Skilled in preparation, approval, and dispatch of prototype, tooled, and PPAP parts; proficient in defect analysis using QC Story, 8D, 7 QC tools, ERA/ICA/PCA, and DMAIC problem-solving approaches.
  • System Validation & Standards: In-depth knowledge of DVP creation, system validation cycles, PPAP, PFMEA, MSA, SPC, GD&T, DCP, and process estimation for new part costings.
  • ISO TS 16949 & QMS Compliance: Implement and monitor ISO/TS 16949 standards for component-level testing during proto and serial production; lead proto builds, FTR events, homogenization reviews, and ensure adherence to QMS requirements.
  • Continuous Improvement & Cost Reduction: Skilled in VAVE proposals, process optimization, and lean manufacturing tools including VSM, PDCA, Kaizen, QFD, PQAL, DSTR, 5S, TPM, TPS, SPC, RR, MSA, achieving cost, quality, and efficiency improvements.
  • Engine Cooling & Thermal Management Expertise: Unique Roles & Responsibility

Education

B.E- Mechanical Engineering - undefined

RM Valliammai Engg College
Chennai

DME-Mechanical Engg - undefined

Vignesh Polytechnic
Tiruvannamalai

Skills

  • EV Product Design & Development
  • Quality Systems & Tools
  • Lean Manufacturing & Six Sigma
  • Cost Saving/VAVE/TQM/TVM
  • Business Analysis & Requirement
  • Vendor Development for EV Parts
  • Programme Management
  • New Product Testing & Validations
  • Leadership & Strategic Management
  • Project & Risk Management
  • Critical issues & resolutions
  • Team Building & Training

Certification

  • Certification in IATF AUDITER
  • Six Sigma Green Belt.
  • Lean Manufacturing Champion
  • TPS, TPM, QMS, SPC, DOE,7QC, MTTB, MTTR, OEE&Capacity.
  • Global Kaizen Award 2013&14
  • Best Employee Award 2017
  • Star of the Year Award 2021
  • Motherson Quality Circle Award
  • Best VAVE Award Cost Saving

LANGUAGES KNOWN

English
Tamil
Hindi

Accomplishments

  • Model Changeover time reduction from 5 to 2 NB furnace by optimizing the braze pattern leads the power cost saving per annum 3.5 million.
  • Eliminating SS304 Material for Brazing using Carbon bar innovative Method and proven with proper testing and validation across all the 5 Models and Cost saving 7.2Million/Year
  • Innovate designed the Condenser End plate and proven the design and Cost saving per year is 6.85Million.

Awards

Best Employee Award 2013, 2014, Best Cost Saving Project Award 2014, Global Best Kaizen Award -2015, Innovative Design Award -2017, Problem Solving Award - 2019, Corporate Quality Circle Award -2022

Patent Applied

Without End Plate Design for Condenser.

Timeline

EV 2W&3W OEM NPD AGM- Engineering

GREAVES COTTON LIMITED
05.2024 - Current

EV Motor Design & Development SPECIALIST

SONA COMSTAR AUTOMOTIVE TECHNOLOGIES INDIA PVT LTD
07.2022 - 05.2022

NPD - Manager Engineering

ATHER ENERGY PVT LTD
05.2022 - Current

Team Lead R&D Specialist

HANON AUTOMOTIVE SYSTEMS INDIA Pvt Ltd
10.2018 - 07.2018

Senior R&D Specialist

MAGNETIC MARELLI India Pvt Ltd
06.2016 - 09.2016

B.E- Mechanical Engineering - undefined

RM Valliammai Engg College

DME-Mechanical Engg - undefined

Vignesh Polytechnic

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Jayaprakash Kamaraj