RAJARAJAN MG
CHENNAI
Summary
Accomplished Senior Lead Engineer with a proven track record at Hinduja Tech Ltd., specializing in projects for material development and cost optimization for automotive components. Expert in project management and process improvement, significantly reducing market claims by 1.4%. Demonstrates exceptional skills in manufacturing processes and requirements analysis, fostering innovation and quality excellence.
Overview
11
11
years of professional experience
1
1
Certification
Work History
Senior Lead Engineer
Hinduja Tech Ltd.
10.2023 - Current
- To Study and Develop materials for automotive components through competition benchmarking, technology scouting, literature survey and simulation analysis to choose best suited one to fit application or service
- Material validation and test method development in accordance with ASTM, ISO standards
- Overseeing conceptual designs & studying part drawings; setting-up specs
- & other technical data based on new product requirements
- Designing, documenting & detailing out all physical aspects of product line by generating 3D CAD layout and BOMs with designers & engineers
- Working in synergy with client / manufacturing facility / engineers to analyze and rationalize designs of existing/new components
- Studying existing materials used for part production and thriving to identify alternate materials to produce parts at optimized cost meeting functional & performance requirements
- Driving VAVE actions by building cost reduction strategies in line with project requirements to position components within target budget
- Translating customers' needs & requirements into detailed project plan
- Auditing existing suppliers for ensuring compliance to engineering requirements/statement of work and shop-floor GEMBA
- Ensuring product compliance to regulatory standards
- Executing fit-for-purpose testing as per target product application
- Performing root cause analysis of product quality related issues
- Experience to use Statistical tools for evaluating raw material suppliers and conducting audits.
Associate Manager - Research & Development
Apollo Tyres Ltd.
12.2017 - 09.2023
- Led specialized technology and VAVE projects for new process & product development to improve the functional & performance requirements to ensure organizational commitment to outstanding quality and customer trust
- Implemented KAIZEN in Tyre Building process by eliminating manual intervention and implementing robust automation process to control non-conformance and improve productivity.
- Instrumental to automate process monitoring and safety assurance of retread tyre curing process in electric chamber through Data logger and safety interlock systems
- Initiated process improvements based on thorough analysis of internal operations data resulting in enhanced productivity levels.
- Managed cross-functional projects, ensuring timely completion and alignment with company objectives.
- Ensured fitment of commercial Vehicle Tires in line with application requirements thereby downsizing the market claims/complaints percentage from 6.5% to 1.4% across South & West India
- Developed test compounds by mixing, molding, and verification of compounds rheological, physical, and ageing properties in lab scale
- Used SAP for BOM creation, raw materials test tracking and calculating costs for development of rubber compounds
- Performed technology scouting of material reducing cost of compounds
- Coordinated bulk factory trials with production team to improve efficiency of mixing process
- Drove raw material trials for rubber compound mixing and process optimization; conducted internal process and product audits
- Developed process specifications, work instructions, SOPs, control plans, and process FMEA documentation
- Analyzing product failures caused by compound variations and developed necessary action plan as per CFT methodology
- Utilized DWM & PDCA to improve productivity, quality, scrap reduction
- Instilled a culture of continuous learning & development and high performance in department by assessing team members' competency.
- Initiated process improvements based on thorough analysis of internal operations data resulting in enhanced productivity levels
Technical Engineer - Research & Technology - Raw Material & Compound (Development & Evaluation)
Thejo Engineering Limited
08.2013 - 12.2017
- Slashed cost through scrap reduction from 1000 kg to minimum level in compounding division through lean manufacturing techniques
- Developed new rubber compounds and products such as Compression Moulded, Roto-cure, Autoclave, and Hot Water Curing (Ebonites) Rubber
- Undertook compounding and processing of various elastomers (NR, SBR, EPDM, CR, IIR, NBR)
- Executed development projects with adhesive division to improve viscosity, material bonding strength and shelf life in cold vulcanizing adhesive exporting to Middle East
- Experience in operating laboratory equipment such as Mooney Viscometer, Rotor-less Rheometer (MDR), Universal Tensile Testing, Din Abrader, Goodrich Flexometer, Dispersion Analyzer, so on
- Performed technical lab test operation (compound and raw materials inspection) as per ASTM, IS, and DIN standards
- Executed tests, including material analysis and physical examinations of compounds & products derived from rival samples
- Revamped compound mixing procedures, process parameters and standard operating procedures for production optimization
- Coordinated ISO Audit, Documentation , NC review & closure.
Education
No Degree - Rubber Technology
Indian Institute of Technology, Kharagpur
10.2015
Bachelor of Technology in Rubber & Plastics Technology - Rubber & Plastics
Anna University, Madras Institute of Technology, Chennai
Chennai, India05.2013
Skills
- Manufacturing
- Requirements Analysis
- Quality Control
- Project Planning
- Project Management
- Process Improvement
- Manufacturing Processes
- Root Cause Analysis
- Project Estimation
- Cost Analysis
- Design development
- Material Selection
- Product Development
Languages
English
Bilingual or Proficient (C2)
Hindi
Intermediate (B1)
Tamil
Bilingual or Proficient (C2)
Certification
- ISO 9001:2015 Training by DNV-GL
- TRIZ Methodology for X 2022
- Quality Management Systems (PPAP, APQP, FMEA, DVP, SPC, MSA, Control Plan)
- CATIA V5 - Design Tool for Automotive Parts Development
Affiliations
- Member of Indian Rubber Institute (IRI), Chennai
- Member of All India rubber Industries Association (AIRIA)
- Member of Indian Plastics Institute, Chennai
- Member of ACS, American Chemical Society
- Member of Tire Retread & Repair Information Bureau, TRIB
- Imperial Society of Innovative Engineers
- International Association of Engineers
Additional Information
- Exposure to manufacturing processes of parts such as extrusion, injection molding of plastic components.
- Support to product development team to conduct validation and provide feedback
- Planning project requirements including resources planning, work breakdown, project milestones, critical path analyses, risk management, SWOT analysis, cost/benefit analysis, staffing and project budgeting.
- Driving CFT portfolios to strength process/product requirements consistently improving QCD (Quality, Cost & Delivery).
- Awareness on ISO , IATF standards to ensure process and products are meeting the standard and specification ensuring zero non-conformance
Accomplishments
1. Field complaints/claim reduction to 1.5 % from 6.5% within three months through CFT approach and GEMBA at customer end.
2. Cost optimization through localization and resourcing of high value items
3. Appraised for implementing a process control system in retreader zone to optimize the mass balancing in tubeless tyre
4. Awarded for being the customer centric technologist to produce sound and quality consistent end product to Satish Dhawan space center
5. QCC nomination for best deployment of quality control tools
to optimize the gauge at shoulder in truck bus radial tyre
Timeline
Senior Lead Engineer
Hinduja Tech Ltd.
10.2023 - Current
Associate Manager - Research & Development
Apollo Tyres Ltd.
12.2017 - 09.2023
Technical Engineer - Research & Technology - Raw Material & Compound (Development & Evaluation)
Thejo Engineering Limited
08.2013 - 12.2017
No Degree - Rubber Technology
Indian Institute of Technology, Kharagpur
Bachelor of Technology in Rubber & Plastics Technology - Rubber & Plastics
Anna University, Madras Institute of Technology, Chennai
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