NAVANEETHAN SURESHKUMAR

• Successfully increased output from 225,000 units to 395,000 units by modifying the third form done in a 63 T press instead of hydraulic actuators.
• Lowering rejection rates through improved quality control and process adjustments, according to the technical specification for ERC clips given by RDSO through SOP, training, and data collection and analysis.
• Led initiatives and achieved a reduction in rejection rates from 15% to 8% through process improvements, Tool & Die improvements, and scheduled preventive maintenance.
• Implemented SMED techniques to reduce tool downtime from 4 hours to 1 hour.
• New product development of SKL clamps for Delhi Metro, Gujarat Metro, and Chennai Metro.
• For SKL Clamps, a new method of induction heating developed through INTERPOWER and commissioned to avoid bending during heating.
• Implemented a strong safety culture and strict operational discipline, resulting in zero lost-time injuries.
• Monitored inventory levels and restocking schedules to avoid production delays from unavailable materials. Regular monthly audits are conducted to maintain KANBAN, and actions are taken for irregularities.
• Indirectly contributed to improving profitability through effective oversight of operations and customer service.
• Identified and resolved process and equipment issues to minimize production downtime.
• Evaluated employee performance and provided feedback and training as needed.
• Collaborated with technical and administrative teams to develop and implement successful corrective plans.
• Provided direction and leadership to all levels of employees and managers.

• Successfully brought new products on time and within budget, meeting both commercial and technical targets: bevel gears for Renault-Nissan, Schaeffler, hydraulic gears for Danfoss Italy, and Ev Hub shaft for SEP India Automotive Ltd.
• Implement strategies for cost reduction and efficient resource management throughout the NPD process, as per NPD Cluster procedure trained by ACMA. With gate reviews and 6M planning.
• Driven continuous improvement in NPD processes, leading to faster development cycles and improved operational efficiency, such as implementing E MAG machines for machining bevel gears, and the implementation of plunge grinding instead of traverse grinding for shoulder grinding, etc.

• Built and maintained strong relationships with internal and external stakeholders, ensuring their needs and expectations are met.
• Identified and built relationships with new suppliers for new projects, and new components.
• Coordinated with Marketing to increase the market position and revenue
• Ensuring all new products comply with regulatory standards, and maintaining a full documentation trail, including APQP and PPAP, both in the customer portal and in-house portal.
• Mentoring and building a strong NPD team, establishing best practices, and driving continuous improvement.

• Lead the conceptualization and design of straight bevel gears through KISSSOFT and NX, ensuring optimal performance by selecting gear parameters like module, face width, pressure angle, and number of teeth, as per the customer's part print.
• Projects executed for MARS, GETRAG, PUNCH POWER TRAIN, TORQUE MOTORS, SCHAEFFLER INDIA, CARRARO, and LUCID MOTORS.
• Improved the lifespan of gears and successful validation results above target values by OEM through specified material selection from approved sources, forging and coining methods, error-proof CNC machining for dimensions, proper heat treatment for metallurgical results, and coating processes.
• Brought new, high-performing straight bevel gears to market that meet critical customer needs in diverse applications, not only in automotive, but also in industrial machinery.
• In all projects, forging simulation is carried out compulsorily as a regular part of work through FORGE 11 to freeze the part process design and tooling design.
• Lead collaboration between engineering, manufacturing, quality control, and supply chain teams to ensure a smooth and integrated development process as a project manager.
• Pioneering new or improved manufacturing methods, such as developing a direct hard milling process through KALYANI ADDITIVE MANUFACTURING for precision forging dies for straight bevel gears, to boost productivity and lower costs.
• Implemented rigorous quality control measures and advanced testing procedures by CMM, specific dedicated process fixtures, and gauges to increase gear reliability and quality.
• Mentored a high-performing team of engineers and technicians, and fostering a culture of innovation and continuous improvement.

• Lead the conceptualization and design of straight bevel gears through KISSSOFT and CATIA, ensuring optimal performance by selecting gear parameters like module, face width, pressure angle, and number of teeth, as per the customer's part print.
• Projects executed for 3DU, ORLEIKON, GRAZZIANO, TATAMOTORS, 9X 13, CPFL, FORD, DANA M150, and ZF.
• Improved the lifespan of gears and successful validation results above target values by OEM through specified material selection from approved sources, forging and coining methods, error-proof CNC machining for dimensions, proper heat treatment for metallurgical results, and coating processes.
• Brought new, high-performing straight bevel gears to market that meet critical customer needs in diverse applications, not only in automotive, but also in industrial machinery.
• In all projects, forging simulation is carried out compulsorily as a regular part of work through Q FORM to freeze the part process design and tooling design.
• Lead collaboration between engineering, manufacturing, quality control, and supply chain teams to ensure a smooth and integrated development process as a project manager.
• Pioneering new or improved manufacturing methods, such as developing a direct hard milling process through Vendor BAPAA ENGINEERS for precision forging dies for straight bevel gears, to boost productivity and lower costs.
• Implemented rigorous quality control measures and advanced testing procedures by CMM, specific dedicated process fixtures, and gauges to increase gear reliability and quality.
• Mentored a high-performing team of engineers and technicians, and fostered a culture of innovation and continuous improvement.
• Increased customer satisfaction by addressing and resolving concerns in a timely manner.
• Analyzed customer feedback data to identify areas of improvement and develop solutions.
• Collaborated with other department managers on cross-functional projects, fostering a cooperative atmosphere that drove overall organizational success.

• Led and oversaw all aspects of the piston ring production line, ensuring daily targets and deadlines were met, especially in the plasma cell, plasma spraying of top rings as Cell Owner.
• Implemented changes to production methods, resulting in a measurable increase in overall equipment effectiveness (OEE) and a significant boost in output from 1,500 units to 3,000 units per shift.
• Played a key role in the successful introduction and scale-up of the Synchroniser ring, as a diversification of the company portfolio. Moly spraying, ID grinding in initial phases, later introduction of MIBA frictional strips.
• Selected for orbital cold forming project. Contribute to new product development: Identify tooling and fixture requirements, calculate capital expenditure (Capex), and provide technical sign-offs for new components, such as gears and other transmission parts.
• Assist in budget planning, and allocate resources like machinery, inspection equipment like CMM, and raw materials effectively.
• Streamlined operations, along with CFT, by identifying necessary processes to achieve the quality of bevel gear dimensions as per customer part print.
• Established quality standards in all manufacturing processes of forming, machining, heat treatment, and surface coating.
• The design process was carried out using CATIA, and simulation was performed by DEFORM.
• Facilitated cross-functional collaboration to drive successful project completion within deadlines.
• Bevel gear projects were initiated and completed sector-wise.

Passenger car segment - Hyundai, Fiat, Kia, Maruthi.

Tata Motors

Heavy commercial vehicles – TATA Motors,

ASHOK LEYLAND, FORCE MOTORS, DANA, AAM.

Off highway vehicles - TAFE, INTERNATIONAL TRACTORS

JOHNDEREE

3-wheeler - Bajaj Auto, TVS Motors.

• As DGM in process engineering and NPDS, I successfully increased production capacity by optimizing machine utilization and reducing non-productive time.
• Drastically reduced rejection rates and improved product quality by implementing robust quality control protocols, and troubleshooting defect causes.
• Led the implementation of advanced forging techniques, like near-net-shape forging, which eliminated or minimized post-forging machining.
• Led department-wide initiatives using techniques like Kaizen and 5S to drive sustained improvements in productivity and quality.
• APQP, PPAP, PFMEA, SPC, and MSA completed for all the projects stipulated above.

• Created 2D drawings, optimized part geometry, designed complex features, simulated and analyzed designs, and troubleshot tooling issues. Provide technical support, manage project timelines.
• Collaborated with cross-functional teams, communicated with suppliers, created bills of materials (BOMs), and maintained tooling documentation.
• Reduced lead time, decreased material waste, reduced tooling costs, improved dimensional stability, increased first-pass yield.
• Die casting tool design and manufacturing for the following.

Tata 407: Radiator Front Case

Bajaj Auto & Greaves Cotton - Crank Case

Gabriel India - Dust tube cover and spring adjuster.