PRABHU SELVARAJ
CHENNAI
Summary
Results-driven Manufacturing Engineer with over 10 years of experience in NPI, assembly process development, line layout design, and tooling implementation. Led initiatives to launch new products, optimise cycle times, and enhance quality through error-proofing solutions. Skilled in PFMEA, process documentation, and Lean manufacturing, driving cross-functional collaboration to achieve manufacturing excellence aligned with safety, quality, delivery, and cost objectives.
Overview
2
2
Languages
11
11
years of professional experience
Work History
Assistant Lead Engineer
Vestas wind technology
Chennai
06.2023 - Current
- Lead industrialization and assembly process development activities for wind turbine generator 7 & 15MW platforms.
- Developed assembly process sequences, process flow diagrams, work instructions, and manufacturing documentation for DPT and PPT builds.
- Reduced assembly time by 15% through process optimization and standardized manufacturing practices.
- Executed 20+ ECNs for generator and hub products, updating manufacturing process documents to uphold product quality during serial production.
- Supported NPI and production ramp-up activities across 3 manufacturing facilities in Germany, China, and Denmark.
- Facilitated commissioning, factory readiness, process validation, and transition from product development to serial production, ensuring smooth operational handover.
- Collaborated with engineering, quality, and operations to streamline processes and eliminate inefficiencies.
- Led ergonomic assessments and implemented safety improvements in assembly processes, reducing awkward postures and repetitive movements by ~20%, while enhancing operational efficiency and ensuring compliance with EHS standards.
Assistant Manager
Borgwarner cooling systems
01.2016 - 06.2023
- Managed capital projects, overseeing equipment selection, installation, commissioning, and contractor management to ensure timely project completion
- Successfully managed 50+ PPAP approvals and manufacturing readiness reviews for global OEMs, including GM, Ford, Daimler, Caterpillar, Tata Motors, Ashok Leyland, Volvo and Force Motors, achieving on-time launch and customer compliance requirements
- Led development of manufacturing and quality documentation for 50+ new projects, ensuring compliance and supporting on-time product launches
- Improved manufacturing productivity through line balancing, cycle time reduction, and process optimization initiatives
- Achieved approximately 25% cycle time reduction through Lean Manufacturing and manufacturing flow optimization initiatives
- Reduced component manufacturing costs by 12% through Design for Manufacturing initiatives in drive line production
- Mentored team of 6 to achieve production and quality milestones, utilising structured problem-solving and continuous improvement methodologies
- Developed and implemented new manufacturing processes, assembly equipment, fixtures, and tooling solutions
Education
Bachelor of Engineering - Mechanical Engineering
Sathyabama University
Chennai, India01-2015
Skills
- Lean manufacturing
- Continuous improvement
- Waste elimination
- Standard work
- 5S methodology
- Value stream mapping
- New product introduction
- NPI strategies
- Process flow diagrams
- Final assembly processes
- Quality assurance
- Root cause analysis
- PPAP documentation
- Process validation
- DMAIC framework
- Operations management
- Material flow planning
- Line balancing
- Ergonomic Assessment
- Layout Planning
- Software proficiency
- SAP
- SolidWorks
- Creo Illustrate
- Microsoft Office Suite
- Office Suite expertise
- Creo Illustrate
- Microsoft Office Suite
Websites, Portfolios, Profiles
https://www.linkedin.com/in/prabhu-selvaraj-25b0bb87
PROJECTS
- Final Assembly Station Development, 2018 - 2019, Designed and deployed final assembly station for fan and drive units., Integrated PLC-controlled torque application and traceability systems., Achieved 100% component traceability., Reduced changeover time by 25% using Lean principles and optimized tooling concepts.
- Fan Balancing Process Improvement, 2018 - 2019, Commissioned high-precision balancing equipment., Developed custom fixtures for multiple product variants., Improved FTT by 18%.
- Load Gate Monitoring System, 2019 - 2021, Implemented process monitoring system for bearing pressing applications., Reduced warranty complaints by 26%.
- Flexible Trimming Machine, 2021 - 2022, Developed a multimodel fan trimming solution that eliminated 100% of dedicated diameter-specific tooling, reduced tooling costs by 80%, improved process capability, and decreased customer complaints by 75%.
Accomplishments
- Assembly Time Optimization
- Led a team and reduced assembly time by 15% through process optimization measures.
- Cycle Time Reduction
- Achieved approximately 25% cycle time reduction via Lean Manufacturing initiatives.
- Lean Manufacturing Success
- Reduced changeover time by 25% using Lean principles and optimized tooling.
- Product Yield Improvement
- Improved FTT by 18% through custom fixtures development for product variants.
Languages
English
Advanced
C1
Tamil
Advanced
C1
Timeline
Assistant Lead Engineer
Vestas wind technology
06.2023 - Current
Assistant Manager
Borgwarner cooling systems
01.2016 - 06.2023
Bachelor of Engineering - Mechanical Engineering
Sathyabama University