MANOHAR ASHOKAN, DME, BE

• Global Brands : Fiat, Jeep, Citroen, Abarth, Free2move, Peugeot, RAM, Maserati, Dodge,
Lancia, DS, Chrysler, Alfa Romeo & OPEL

Responsibilities :

Responsible For Global Manual Transmission & Driveline Testing & Validation for Peugeot & FIAT Brands Including Advance Automatic Transmission projects
• Lead the Engineering & Validation Group with 40 heads and Test lab, test facility and Test asset Management.
• Prepare Project plan, stake holder alignment, Project Kick-Off and Execute Development and Validation projects.
• Estimation of Budget Interms of headcount, material, vehicle, and outsourcing activities and ensure track record for management update.
• Workload assessment, capacity planning to ensure testers capacities are maximized and sufficient.
• Understand and implement Engineering best practice and validation procedures for various types of research and customer projects.
• Value Optimization in Powertrain Parts, ECR and issue Management on PLM and Track record for the same
• Generate service bulletin to reduce warrant cost at dealer / After sales and Support to TPC and TLC cost of product.
• Engage with supplier & plants to bringdown product TLC cost by Optimizing design, material, sourcing change without quality confermice.
• Lead the Root cause Analysis team to ensure all Customer issues from Transmission & Driveline solved on time and plan dealer visits.
• Closely with Global Vehicle plant, Powertrain plants (IAP, NAFTA, EMEA, LATAM) for Development activities and Customer issues
• Supplier Visits for Design & process review, drawing updation, Solve Quality Issues, Cost & timing Optimization.
• Generate Test procedure for Transmission, Clutch & DMF and External shifter according to market region with Engineering techniques.
• Selection of test benches, develop the varies test benches & set-up according to validation need.
• Modification of existing test benches according to test requirements & test execution
• Milestone review meeting Program management, PSA & OPEL Germany to discuss on validation topics.
• Optimize set-ups where necessary give input and ideas for optimization of the lab.
• Skill-Up plan for team, Goal setting and appraisal, Hike assessment along with HR & management, reward, and Recognition to the team
• Experience in LabVIEW, Matlab and Reilhofer software for NVH measurements / data analysis.
• Creating, managing, and delivering multiple projects on-time and to budget

• Planning & execution of Prototype validations for Bearings, Gears, Housings, Sensors & Other mechanical components
• Ensure on time completion of validations in field, tear down analysis, report preparation & report publish
• Discuss with supplier on validation results and demand engineering improvement and CAPA against observations
• Review of validation procedures and execution of the same and ensure daily status of validations
• Technical support for gearbox and drive train related accessories to operation and Maintenance
• Provide inputs to design team for new product development
• Review & analysis of gearbox validation report (noise, vibrations, speed, torque, temperature etc.)
• Team managing of 7 Senior Engineer and 4 Engineers and work allocation / get updates

Define list of validations, study of test procedures, planning of measuring instruments & bench/vehicle allocation
• Regular Interaction with drivetrain team in Nissan Japan on test planning, technical queries & result discussion
• Cost estimation for each validation, monthly testing budget provision, Bench resource allocation
• To plan and conduct drivetrain units & controls validation tests in terms of quality, cost and time.
• Maintain R&D lab test benches, measuring instruments, sensors, calibration planning and ensure utilization.
• Proto validation of Renault Nissan transmission on bench level as well as vehicle level
• Handling of strain gauge, bridge box, data logger, tough book, knob load cell shiftability software
• Bench marking of competitor vehicles for manual transmission shiftability (GSQA) & clutch pedal operatability.
• VOC collection, dealer visit, field failure analysis, technical solution, consolidates TM issues and RCA/CAPA
• Teardown analysis of competitor vehicle transmission, analysis & prepare comparison report.
• Analysis for field returned transmissions & drive shaft and perform duplication test at vehicle level for conclusion.
• Technical training to dealers & customers related to gearshift pattern & clutch operatability while vehicle driving.
• Review, update, track multiple validations (Bench & vehicle level) & ensure on time completion.
• Successfully completion of Testing & validation completion of RENUALT-KWID & NISSAN-DATSUN Transmissions

Meeting production targets and taking countermeasures for the variance in plan vs. actual in & testing Cell.
• Elimination of NVA, cycle time reduction, improve safety, Improve machine utilization in Testing cell.
• Support for R&D team transmission validations, understand & execution of validations & result analysis.
• Testing of customer return transmission on bench for concern duplication, root cause analysis & report
• Preparation of testing work instruction, one-point lesson, Poke-Yoke,5S, cost reduction on transmission reworks
• Test bench set-up change & execution new model gearbox validation according to duty cycles
• Ensure 100% utilization of all 3 type test benches, perform equipment calibration & document records.
• Execution of Test bench AMC with supplier & ensure condition of benches always up.
• Implementations of product quality, productivity, safety, operating cost & coordinate with CFT’s
• Implementation & monitoring utilization of resources such as manpower, machinery in production cell
• Analysis of gear NVH order analysis during testing with Reilhofer system and post analysis
• Develop the technicians by provide technical/communication skills and maintain skill matrix data.
• Handling of customer complaint, failure parts analysis, concern duplication, report preparation & conclusion
• Maintain 5S, IATF audit preparation, EHS documentation, JIT and implementation PDCA.
• Handling of accelerometers, portable sound level meters, speedo meter etc...

Planning & execution of gearbox testing & validation on bench according to customer requirements.
• Identify roadblocks on each validation (cost, resources, proto parts availability) & counter action against gaps to meet validation time plan.
• Prepare, review, approve & publish the gearbox validations report to discuss with suppliers on validation results & global validation team.
• Planning on validation budget, headcounts, consumables, bench resources for management review
• Discussion with suppliers on proto parts availability, parts development led time to adhere global validation plan.
• Preparation of test bench, preparation of gearbox, perform flushing with 200 rpm before validation.
• Hands on experience in assembly of gearboxes with gears, bearings, housings, shafts, ply setting etc.
• Mounting of vibration sensors, sound micro phone, PT100, telemetry for torque measurement
• Gearbox test for three different speed & torque conditions as per test specification & confirm vibration.
• Measurement for Noise, vibration, oil purity for each load steps by using FFT & CPB analyzer (B&K Pulse)
• Detect the gearbox noise/vibration issues by spectrum analysis (frequency analysis graph)
• Root ` noise/vibration issues & other failures while validation
• Team management,5S, 8D analysis, Poke-Yoke, skill development plan & execution
• Ensure 100% utilization of all 3 test benches, perform equipment calibration & document records.

• Company Overview: Mfg
• Of Bike & scooter OEM based in India
• Hands on assembly experience in Engine line from crank case to engine leak testing
• Perform engine assembly operation as per TMOS standard
• Ensure quality parameters are within limit for entire engine while assembly operation
• Proto part assembly & vehicle proto testing along with R&D team for TVS APACHE Project
• Disassembly of entire engine for rework-based complaint raised while engine testing
• Carry out internal parts replacement, Re-assembly & Perform Re-testing to ensure defect free engine
• Mfg
• Of Bike & scooter OEM based in India