Vivek Rai
Powertrain Development Manager With 18 Years Of Experience
Pune
Summary
Engine Testing Coordinator supporting engine localization programs through bench testing, car-level testing, and DVP preparation for new powertrain releases (1.0L TSI and 1.5L TSI evo engine).
Delivered several stagewise, technology driven and legislation driven engine localization programs for Kushaq, Slavia, Virtus, Taigun and Kylaq vehicles.
Leading Flex fuel program for India.
Coordinates test activity across planning, assembly, quality, and supplier teams, while resolving engine issues and preparing teardown reports for engineering release.
Powertrain coordinator for field issues. works along with Quality, field support team for field complaints.
Overview
18
18
years of professional experience
Work History
Co-ordinator – Engine Testing
Skoda Auto Volkswagen India Pvt. Ltd.
2019.07 - Current
- Designation: Chief Manager – Powertrain Development
- Leading Engine Testing team in India that supports engine localization program with tests for engine release in local market
- End to end testing coordination for above programs, timely delivery and seamless execution to meet SOP timeline
- Led engine testing team in India to support engine localization program, conducting tests for engine release in local market
- Reporting testing status in engine Pilot hall (VW group term for senior management review)
- Coordination with engine planning, engine assembly, engine and vehicle Quality
- Resolved engine-related issues for plant quality and field quality.
- Technical lead for Flex Fuel engine development
- Cost reduction on existing powertrain to improve business case
- Action on management drive feedback, press feedback for product optimization
- Powertrain strategy – Vision 2030 (from ICE portfolio and future technology roadmap)
- Alternate fuel strategy (CNG, E25, Flex Fuel)
- Spearheaded localization of 1.0L TSI and 1.5L TSI engines for multiple vehicle programs, ensuring alignment with market needs
- Working with Technical teams from Skoda, AUDI and Volkswagen AG.
- Mitigated risks related to Covid19, ensuring timely delivery of programs in line with pre-Covid19 target timelines
- Current Role:
- Job Title: Co-ordinator – Engine Testing
Founder Director
Affinity Automotive Solution Pvt. Ltd.
2019.01 - 2019.06
- Consulted in automotive domain, providing expert insights to enhance product development and testing processes
- Delivered specialized services in powertrain measurement techniques and test rig development to support engineering projects
- Area of services:
- Special measurement technique for powertrain (Piston telemetry, Liner and Flame deck temperature measurement, Valve train dynamic testing, strain gauge application, instrumentation of cylinder head for combustion pressure measurement)
- Product development support (Expertise in Oil Pump, Water Pump, special purpose coatings)
- Engineered friction solutions to optimize performance and reliability in automotive applications
- Friction engineering
- Electric 2W development support (market research, legislation, technical opportunities and challenges, sourcing and product development)
- ECU development for a CNG kit manufacturer
Deputy General Manager
FEV India Pvt. Ltd. (Fully owned subsidiary of FEV GmbH)
2011.03 - 2018.12
- Business Unit Leader: Gasoline Powertrain Development (Year 2015 - 2018)
- Strategic planning of resources to take care of current needs and with focus on future technology trend and demands from OEMs.
- Reporting of finances, business scenario, updates on acquisition, market demands and resource planning to India and Global management
- Drove growth of business unit by increasing sales volume, enhancing technical competencies, and exploring new business opportunities.
- Responsible for business acquisitions, promoting technical services, workshops at customer locations, advising customers on low friction technologies & advanced mechanical development methods, establishing cooperation with suppliers of components including oil to provide low friction technologies for OEMs.
- Overall responsible for Gasoline Powertrain development
- Built a goal-driven, value-centric business unit aligned with FEV vision and mission.
- Recruitment, mentoring, guiding team under responsibility. Arrange suitable training (either at India centre or at Global centres as per availability of projects and expertise)
- Building strong customer relationships by delivering strong values, supporting customer's needs and ensuring a close working relationship with existing customer while also providing focussed efforts to add potential customers
- Identified emerging technical areas based on market trends, investing in preparations for future technology and business requirements.
- Developed local team and competency to deliver Turnkey powertrain development programs with >90% responsibility from India centre.
- Program manager for strategically important projects where customer / technology is in high focus.
- Responsible for test bench revenue, test bench uptime for test benches under responsibility of Gasoline development & mechanical development teams.
- Department manager: Mechanical Development and Friction Technology (Year 2015 - 2018)
- Responsible for acquisition and execution of mechanical development and validation testing projects (Diesel, Gasoline, CNG, LPG)
- Responsible for acquisition and execution of friction engineering projects including CO2 reduction projects which were delivered together by FEV India and FEV Germany
- Develop know-how, foster knowledge and experience exchange through trainings, interactions and participations of team members in global project
- Support FEV global projects in Friction and mechanical development to utilize BCC advantage
- Build strong network and relationship among OEM partners to understand their current and future needs in Mechanical development and friction engineering support.
- Ensure continuous workload for test benches (Mechanical development and friction test bench)
- Develop new capabilities in line with OEMs requirement and technology trend (several testing process, rigs, methods and capabilities were driven by OEMs challenging requirements)
- Strengthen FEV position in these technical areas and present as market differentiator in these technical areas. (due to unique positioning we did not depend on pricing to win projects in Friction & Mechanical Development)
- Chief Engineer – Mechanics and Tribology (FEV Global X-Function, Year 2018):
- Harmonizing FEV global locations process, practices and methods in mechanics
- Following unified guidelines, accessing global know-how and experience, training teams across different FEV Locations
- Increasing customer experience while working at various FEV locations by ensuring that customer specific, test procedures, guidelines, requirements and lessons learnt are available to local teams.
- Sharing knowledge, providing training on specific topics and working towards FEV flagship program – World Class Testing, Mission 2020
- Chief Engineer – Supplier Management (FEV Global X-Function, Year 2018):
- Increasing FEV global reach into prototype supplier database
- Evaluating existing prototype suppliers from India and adding new suppliers based on FEV guidelines.
- Helping FEV global sourcing team, cheaper and faster prototype components from India
- Helping local OEMs with trusted suppliers for prototype sourcing.
- Technical Specialist – Friction Engineering (Year 2013 - 2018)
- I established complete know-how and process of unique FEV Strip down method of friction evaluation. FEV has widest exposure to friction globally with >1000 measurements on over 600 different engines in its database. At FEV India, we did more than 30 engine friction assessment and several friction reduction programs.
- FEV India is known among Indian OEMs for our capabilities and deep understanding of this unique and complex technical domain.
- Engine set up and test bench operation (Year 2011 - 2014)
- Engine preparation (offline and inside engine test bench) for all kinds of testing performed at FEV India including Performance & Emissions, Mechanical Validation, Hot test, Homologation,...
- Responsible for operation of FIVE engine durability test benches
- Responsible for upkeep of test benches and its equipment including their overhauling and maintenance (Dyno, conditioning systems, heat exchangers...)
- Bring FEV global practices and know how to FEV India.
- Key Responsibilities:
Engine Testing Engineer
Tata Motors Ltd. (Engineering Research Centre, Pune)
2010.03 - 2011.03
- Conducted durability and performance testing, evaluated new components for performance and durability
- Field failure analysis, designing test plan for simulating field conditions and validation of solutions for field failures
- Performed field failure analysis, designed test plans to simulate field conditions, validated solutions for identified failures
- Key Responsibilities:
Casting Development Engineer
Hinduja Foundries Ltd.
2008.07 - 2010.02
- Led weight reduction initiatives for cylinder block, developed FMEA and control plan for new product as quality system engineer for MNC OEM.
- Worked on several weight reduction projects and worked as CFT team leader for innovative casting methods program.
- Reporting to Executive Director, Hinduja foundries Ltd.
- Key Responsibilities:
Education
Executive Business Management (PGCBM) -
XLRI,Jamshedpur
Jamshedpur2018-01
Bachelor in Technology, Manufacturing engineering - undefined
NIFFT Ranchi
Ranchi2008-01
Skills
- Engine and car testing
- Powertrain localization
- Test bench operations
- Friction engineering and functional testing
- Project risk evaluation
- Decision modelling
- Team development
- Conflict management
- Stakeholder coordination
- Full product lifecycle development
- Powertrain strategy focusing 2030-35 requirements
- Budget and provisions
- P&L management
- Cost reduction
Accomplishments
- Successful localization of EA211 1.0L TSI engine (Local content >90%)
- Design validation program for critical components - Turbocharger, Fuel Injection pump
- Successful concept preparation for Flex Fuel engine for India market
- Timely delivery of engine localization program for - Skoda Kushaq, Skoda Slavia, Skoda Kylaq, VW Taigun and VW Virtus
- Successful resolution of >15 field complaints from market India related to vehicle programs
Timeline
Co-ordinator – Engine Testing
Skoda Auto Volkswagen India Pvt. Ltd.
2019.07 - Current
Founder Director
Affinity Automotive Solution Pvt. Ltd.
2019.01 - 2019.06
Deputy General Manager
FEV India Pvt. Ltd. (Fully owned subsidiary of FEV GmbH)
2011.03 - 2018.12
Engine Testing Engineer
Tata Motors Ltd. (Engineering Research Centre, Pune)
2010.03 - 2011.03
Casting Development Engineer
Hinduja Foundries Ltd.
2008.07 - 2010.02
Bachelor in Technology, Manufacturing engineering - undefined
NIFFT Ranchi
Executive Business Management (PGCBM) -
XLRI,Jamshedpur
Technical papers and associations
- Technology to Achieve Engine Efficacy: Friction Reduction (Paper ID: 2018-01-0983) SAE Michigan, 2018
- Attribution of engine thermal energy for battery management (Paper ID. PDS084101) ITEC 2017, ARAI
- Technology to achieve engine efficacy - Friction optimization and controlled emissions, (Paper ID. F2018-PTE-264) FISITA 2018, Chennai
- Technical paper abstract reviewer and Session chairman FISITA 2018, Chennai