Rajeev Pillai

10+ years of experience in the Vacuum coating and Thin Films Manufacturing/Production arena with Hands On Knowledge on Thin Film Process, production and Maintenance of Vacuum Systems with a demonstrated record of driving yield and productivity initiatives. Experience in Thin Film Process development & Product Design development by Root cause analysis evaluations as well as process validation for quality assurance for mass production. Energetic leader promotes 10 years of industry experience with superior record of accomplishment. Ambitious and highly motivated Production manager surpasses demanding objectives and achieves or exceeds set goals.

• Production Manager- Oerlikon Balzers Pvt Ltd, Chennai
• Manage manufacturing process to ensure product is delivered on time and under budget while maintaining quality standards
• Plan and execute the production schedule including human and material resources
• Coordinate with vendors, suppliers and contractors to ensure delivery of key materials
• Ensure high customer satisfaction ratings, maintain production goals and reduce inventory carrying costs
• Utilize Lean Manufacturing strategies to improve manufacturing processes and reduce costs
• Design training programs for new employees and ongoing projects to improve effectiveness of existing staff
• Collaborate with receiving and production personnel to review inventory levels and determine shifts in production areas that would limit materials and supplies held on hand
• Manage logistics, shipping, receiving, delivery and distribution including process improvement and problem resolution
• Oversee utilization of staff resources and migrate workers to key areas to optimize productivity
• Rocess Engineer at Automotive Division - IHI IONBOND COATINGS Pvt Ltd, Chennai
• (2016- April 2019 )
• Supervise over all employees with full responsibility for recruiting, interviewing, hiring and training of personnel within 90% of capacity
• Responsible For developing coating process for tools , dies and any other material received for coating
• Responsible For preparation of APQ & PPAP documents
• 7QC tools, Practiced Root Cause Analysis, Failure Analysis of prototype and manufacturing quality assurance
• Lead Internal Auditor for ISO9001-2015 & 13485-2016 QMS and process audit for global process standardization abiding EHS regulations & policies
• Maintain cleaning as well as RO water plants to ensure effective cleaning of tools
• Man management, mentoring, team building, and conflict resolution and facilitation skills
• Abilities in handling multiple priorities, with a bias for action and a genuine interest in personal and professional development
• Participates in cross functional team projects with the production, quality and sales dept as well as customers
• Carryout root cause analysis for any quality failures
• Provide consultations and technical expertise on thin film technologies to coating center staff & on-going quality issues
• Provide Good record keeping , SHE inputs & Communication Skills
• Ensure Customer excellence & Timely delivery of quality products and samples
• Process Engineer-Tool Coatings, IHI IONBOND COATINGS Pvt Ltd, PUNE
• (2013-2016 )
• Daily Planning & Management Of Plant Operations, Corporate Process Engineering, and Business Managers in application development and scale-up of major programs
• Propose new accessories and devise hardware configurations required, that comply with design requirements in terms of functionality and safety
• Provide consultations and technical expertise on thin film technology to coating center staff and on-going quality issues
• Participates in cross-functional team projects with the Sales Department and with customers
• Ability to implement and troubleshoot vacuum coating processes
• Organize the repair and routine maintenance of production equipment’s
• Mechanical design of fixtures
• Root Cause analysis of system & Process Failure
• Maintain and work according to ISO/5S/OSHAS quality systems
• Provide good record keeping and communication skills
• Scientific Officer - HINDH HIGH VACUUM CO PVT LTD, BANGALORE
• (2010-2013 July )
• Development of Optical Coatings for Various Customer Specific Applications
• Evaluation of new materials, methods and technologies for the involved production areas
• Optimization of Thin Film PVD processes to gain better devices, yield, costs and productivity
• Close work together with Equipment and Maintenance Engineers to meet the production specifications and enhance process- and tool stability
• Taking responsibility for the development packages in cooperation with R&D and Product Engineering
• Definition, process qualification and tuning of the new and upgraded tools
• Analysis and reporting of the results to the stake holders
• Participates in cross-functional team projects with the Sales Department and with customers
• Ability to implement and troubleshoot vacuum coating and characterization processes
• Provide good record keeping and communications skills
• Oversee the plants procedures and policies
• Ensure Customer excellence and delivery of Quality products
• Performs related work as apparent or assigned
• PROJECT 9 : “Fabrication of spin valves using sputtering”
• Spin Valve under guidance of Prof:P.S.Anil Kumar (Dept of physics, IISC) comprising of NiFe/Cu/NiFe/FeMn over a substrate was fabricated by “DC magnetron sputtering” technique
• The materials are deposited in the order of desired thickness starting with FeMn followed by NiFe, Cu finally NiFe
• PROJECT 10 : “Design and Development of Bench Top PECVD system”
• PECVD tool under the guidance of Prof.A.K Barua , IACS ,Kolkata for 4 inch sample sizes were designed and developed with one coating chamber and 1 loading chamber respectively
• The tool was designed for multiple layer process involving PECVD and plasma etching
• The tool after successful installation is in operation at HHV SOLAR R &D, peenya, Bangalore
• PROJECT 11 : “Design and Development of Amorphous silicon solar cells”
• Esign and development of small area a-Si solar cells under the guidance of Prof
• Chandan Banerjee, BESU, Kolkata
• The p-i-n layer was deposited on soda lime glass as well as borosilicate glass using PECVD technique
• The scribing of the cell was done by IR and GREEN laser respectively
• Sputtering technique was employed for back contact and front contact deposition.

• MISCELLANEOUS ACHIEVEMENTS: , State level Best Youth award, 2006 holder from Nehru Yuva Kendra, Govt. of India. District level Best Youth award, 2006 holder from Nehru Yuva Kendra, Govt. of India. National Cadets Corps , ‘C’& ‘B’ Certificate Holder PROJECT SUMMARY PROJECT 1 : “Development of polymer coatings for Tableting punch industry using Cathodic arc” A Polymer based Coating for tableting punches was developed using CATHODIC ARC TECHNIQUE .The Ra values of the coating was less than .05 and has been launched in the market after successful trials at reputed Pharma firms like Cipla and Cadillac.
• PROJECT 2 : “Development of Nano Multilayer coatings for Gear cutting tools industry using cathodic arc” A multilayer nanostructured coating was developed for GCT using Cathodic arc process .The tools were coated and performance trials were done at customer sites. The results were encouraging and the coating is to be introduced soon into the market. PROJECT 3 : “ARIES telescopic mirror coating using sputtering” A Coating unit for coating telescopic mirrors with reflective layers using DC Magnetron sputtering. The glasses was initially cleaned using ‘ultrasonic’ cleaning and followed by Plasma glow cleaning. A mask was designed for shielding to get uniform coating on the telescopic mirror. The same unit was used for coating 3.7M, 1.3M, 980mm, 609mm mirrors. The system was designed for ARIES, India. PROJECT 4 : “Valeo car reflector coating system using Plasma polymerization” A coating system was designed for metallization on polycarbonate and PMMA reflectors by the Thermal evaporation, followed by a protective layer coating using ‘plasma polymerization’. The system was designed and developed for Valeo, Italy. PROJECT 5 : “MSHT telescopic mirror coating using sputtering” A Coating unit for coating telescopic mirrors with reflective layers and protective layers using DC Magnetron Sputtering. The glasses were initially cleaned using ‘Ultrasonic’ cleaning and followed by Ion beam cleaning technique. A mask was designed for shielding to get uniform coating on the telescopic mirrors. The unit was used for coating 2.5M mirrors. The system was designed and developed for MSHT, Russia. PROJECT 6 : “Design and Development of cluster PECVD system” A Cluster tool for 4 and 6 inch sample sizes were designed and developed with 5 Deposition chambers and 1 transfer chamber respectively. The tool was designed to be versatile for multiple process involving PECVD, sputtering, Etching, Plasma cleaning and evaporation. The tool after successful installation is in operation at RV College, Bangalore, BESU Kolkata and Mumbai University respectively. PROJECT 7 : “Synthesis of magnetron sputtered microstructures” A Co thin film was deposited by “DC magnetron sputtering” on a Si substrate & an Fe film was deposited by Pulsed laser deposition and were made into desired microstructures by Photolithography( Direct laser beam writing ) followed by Ion beam etching and the AMR property of them are studied by placing the sample(microstructure) with four point connections between two electromagnets followed by the recording of resistance change of the sample with applied magnetic field (MR) and its variation with angle between the current and magnetic field (AMR). PROJECT 8 : “Development of Fe microstructures using PLD and photolithography” An Fe thin film of 100µm thickness was deposited on a GaAs substrate by a “Pulsed Laser Beam Deposition” technique. A microstructure having a pair of contact pads (each 4µm thickness) connected together with wire of 2µm was fabricated out of this deposited Fe film using direct laser Beam writing followed by Ion Beam Etching.