Tharun Raj Balan

Client: Bombardier Aviation, Montreal - Canada (Oct-2022 To Till Date)

• Provide guidelines to the team and ensure compliance with project cost, time, and quality standards.
• Delegate tasks and explain the project lifecycle to team members.
• Collaborate with Manufacturing Engineers, CAM & CNC programmers, and QA teams to achieve business goals.
• Control project activities, schedule timelines, prepare and update project communication documents, and progress reports.
• Schedule meetings to address project status and prioritize deliverables, liaising with the client daily.
• Monitor team performance and key metrics such as on-time delivery, first-time right, and customer satisfaction (CSAT).
• Execute process plans for machining, sheet metal, extrusions, and assemblies in SAP for Bombardier Global Express and A220 aircraft.
• Design and order tools based on manufacturing and engineering requirements using the CAPP tool.
• Address urgent modifications and updates to process drawings and plans from shop floor.
• Prepare and validate documents in Net-Inspect for First Article and Delta First Article processes.

Client: Boeing, India (Oct-2021 To Sep-2022)

Boeing 737, 747 & 767:

• Create and modify installation plans in CAPP and implement standard assembly operations as per Boeing standards.
• Prepare and validate MESA Audit E-Checklists for installation plans.
• Review and create build plans for aircraft structures, systems, and payloads and prepare E-Check, PPCR, RFA-CN, Auto-CERT, IP Cleanups, and MBOM estimation.
• Manage BOM restructuring, IP relations, Task Execution Document creation, and revisions using Product Data Manager (PDM).

Boeing 777-200 eco-D Project:

• Create installation plans in MES for flight test components.
• Review and validate flight test drawings and parts lists.
• Prepare pre-plans, BOMs, job kits, and control points in MES for flight configuration.

Client: Dassault Aviation, GE Aviation, PWA, Honeywell & HAL Divisions

Project I: Project Management

• Provide guidelines to ensure compliance with project cost and quality standards; negotiate with sub-contractors; develop and oversee project plans and activities; handle budgeting and scheduling; support RFQ estimates; manage procurement; prepare and update project documentation and reports; delegate tasks and explain the project lifecycle; collaborate with a diverse team to achieve business goals; ensure on-time completion and approvals.

Project II: New Product Development (Manufacturing/Process)

• Develop and maintain manufacturing process plans for new and legacy products; create detailed operation sheets and tool designs; handle non-conforming product repairs; evaluate customer-driven engineering changes; support day-to-day production; manage heat treatment and special processes; attend audits to address non-conformances; perform root cause analysis and corrective actions.

Project III: Configuration Management

• Monitor and update customer drawings and models with the latest revisions; manage specifications and standards; perform gap analysis on revisions; conduct internal audits to address document control non-conformances; ensure compliance with aerospace standards and customer specifications.

• Identify Prospective Customers: Use business directories, leads from existing clients, and trade shows/conferences.
• Engage with Clients: Visit Purchase departments and plant end-users at power plants, refineries, and various process plants (e.g., cement, steel, chemical, paper, food) as well as OEMs.
• Client Meetings: Arrange meetings or cold call potential clients to introduce the company, product range, provide a product catalog, and share existing customer references.
• Site Assessments: Take product site measurements and propose solutions as needed.
• Follow-Up: Contact existing and potential customers for product reviews, order updates, and pending payments.
• Market Monitoring: Track market conditions and competitors’ products, prices, and sales.

Program: Kaveri Engines & Ghatak Engines

• Engine Configuration: Assess and update engine configurations using the Master Part List (MPL) based on configuration changes.
• Design Changes: Process and approve design changes by analyzing design requirements.
• Action Points and SOPs: Release Action Points (AP) for engine builds/rebuilds to meet test standards and issue Standard of Preparation (SOP) documents for engine build configurations.
• Database Creation and PLM: Create databases according to engine build requirements and implement drawing modifications using PLM (Team Center 8).
• Drawing Management: Retrieve, correct, and upload drawings in PLM, ensuring accuracy with parameters like Drawing Number, Revision, and Originating Group.
• Technical Review: Review and gather technical information from drawings/documents, identify discrepancies, and report them for corrective action.

• Process Drawings: Create detailed process drawings for casing assembly components and parts, incorporating GD&T stack-up analysis to ensure proper fitment for pump assemblies.
• Design Assessment: Review customer data and requirements to develop conceptual designs and implement design changes for finalized drawings.
• Manufacturing Drawings and BOM: Detail manufacturing drawings, generate Bills of Materials (BOM), and perform quality checks to ensure zero defects in drawing quality.
• NDT and Quality Control: Conduct Non-Destructive Testing (NDT) based on geometric and material characteristics, interpret discontinuities, and verify data against acceptance criteria.
• Final Quality Reporting: Prepare final quality reports under the guidance of an NDT Level 3 Inspector.