Solidworks
Sanjay Kr. Chhillar
R&D, NPD, PE Head
Neemrana
Summary
Dynamic Divisional Head with over 24 years of leadership experience in R&D, New Product Development, and Process Engineering within the automotive and manufacturing sectors. Expertise in driving end-to-end innovation—from concept to delivery—with a focus on EV troubleshooting systems, renewable energy optimization, and industrial machinery modernization. Proven track record of achieving operational excellence through strategic cost optimization, enhanced energy efficiency, and streamlined assembly processes. Successfully managed projects valued at ₹30 crore in both greenfield and brownfield initiatives, consistently delivering measurable performance improvements while fostering a culture of robust cross-functional collaboration and innovation.
Overview
24
24
years of professional experience
2
2
Certifications
Work History
Divisional Head, R&D/NPD/PE
Kai India (Kai Group)
Neemrana
07.2020 - Current
- Spearheaded innovation roadmap for 6,000+ consumer products, achieving 37% performance improvement via VA/VE & FEA.
- Implemented Agile PLM tools (ASANA, Joho) to monitor KPIs with 95% accuracy, accelerating time-to-market.
- Directed weekly NPD reviews ensuring strict metrics on quality, cost, and delivery.
- Managed RFQ, costing, BOM, vendor selection, and external testing agency coordination.
- Introduced energy-efficient solutions and assembly simplification aligned with sustainability goals.
Sr. Manager, R&D (Divisional Head)
Carrier Wheels
Shamli
11.2015 - 07.2020
- Led R&D across 3 plants, overseeing wheel load calculations and smart-wheel concept generation.
- Directed process and product development, in-house tool design, and fatigue testing.
- Delivered complete wheel solutions (design, assembly, CED painting), enhancing durability and efficiency.
Manager, Industrial Engineering
Munjal Auto Industries
Bawal
02.2013 - 11.2015
- Optimized welding, gas, and paint consumption, reducing material usage by 14%.
- Improved customer satisfaction by 18% through supplier development and complaint resolution.
- Directed muffler product development (CATCON integration, fabrication, HR painting).
Assistant Manager, PE/ME
GKN Driveline
Rewari
04.2011 - 02.2013
- Initiated VA/VE activities, reducing NPD cycle time by 30%.
- Managed complete driveshaft & axle design, manufacturing, and torque validation.
Sr. Engineer, Tool Room/PE/IE
Minda Corporation
Noida
02.2006 - 03.2011
- Assembly Line Expansion & Optimization: Established 20 new assembly lines, including 12 transferred from group plants, while systematically identifying bottlenecks and optimizing TAKT time to enhance throughput and efficiency.
- Product Development Leadership: Directed end-to-end development and continuity testing for critical automotive components—ignition switches, locks, immobilizer remote keys, fuel caps, starters, and alternators—ensuring reliability and compliance.
- Advanced Automation: Leveraged PLC programming to streamline continuity testing processes, improving accuracy, repeatability, and reducing downtime.
Engineer, NPD/PD/Tool Room
Bajaj Motors
Gurugram
01.2002 - 02.2006
- Led product development for CAM shafts, connecting rods, gears, sprockets, and crank pins.
- Delivered innovative solutions aligned with customer demand.
- Mileage-Enhancing Innovation: Under my leadership, introduced rolling-type arm valve rocker for the Hero MotoCorp Super Splendor motorcycle—a first-of-its-kind innovation—resulting in a 12 km mileage improvement (from 75 kmpl to 87 kmpl), significantly boosting customer satisfaction and market differentiation.
Education
B.Tech - Mechanical Engineering (CIM)
NSIC-TSC
Delhi12-2011
Apprenticeship - Solar Division
BHEL
Gurugram10-2001
Diploma - Mechanical Engineering
Govt. Polytechnic
Manesar12-1998
Skills
- Product Development: DFMEA / PFMEA / DOE / GD&T / DFM / DFA / FEA / VA/VE
- Manufacturing Processes: Casting, Forging, Machining, Welding, Assembly, Painting, Surface Treatment
- Leadership & Strategy: Agile methodology, APQP-PPAP workflows, Change Management, Stakeholder Management, Innovation Culture
- Design & Simulation Tools: Siemens Teamcenter, Solid Edge, SolidWorks, CAM NX10, Ansys
- Standards & Compliance: ISO/IATF 16949, VDA 63/65, RoHS, REACH, BIS, SEDEX
- Emerging Technologies: EV performance & troubleshooting, Battery Life Management & Optimization, Renewable Energy Integration (Solar, Hybrid Systems), Industrial Automation & Factory 40
Software
AutoCAD
PLM
Interests
Sustainbility for the Product and process
Certification
DSIR Certified R&D Professional
Affiliations
# Research work affiliated with DSIR New Delhi
# Transmission work affiliated with RDSO Lucknow
# Emerge technology collaborated with MNIT Jaipur
Additional Information
Completed specialized crash course at ARAI & Tata Motors, Ahmedabad on EV troubleshooting, efficient mechanisms, and solar energy optimization — strengthening expertise in sustainable mobility and renewable integration.”
Innovation
Emerging technology
Accomplishments
- Awarded Best Auditor/Analyzer/Investigator at GKN.
- Directed ₹30 crore brownfield/greenfield projects (Machine Shop & Tool Room – Bajaj Group).
- Earned organizational trust for decisive leadership and technical resourcefulness at Minda Corp.
- Successfully led teams of 19 members, fostering accountability and innovation culture.
Timeline
Divisional Head, R&D/NPD/PE
Kai India (Kai Group)
07.2020 - Current
Sr. Manager, R&D (Divisional Head)
Carrier Wheels
11.2015 - 07.2020
Manager, Industrial Engineering
Munjal Auto Industries
02.2013 - 11.2015
Assistant Manager, PE/ME
GKN Driveline
04.2011 - 02.2013
Sr. Engineer, Tool Room/PE/IE
Minda Corporation
02.2006 - 03.2011
Engineer, NPD/PD/Tool Room
Bajaj Motors
01.2002 - 02.2006
B.Tech - Mechanical Engineering (CIM)
NSIC-TSC
Apprenticeship - Solar Division
BHEL
Diploma - Mechanical Engineering
Govt. Polytechnic