Sainath Ravi

Proposing new Material and supporting analysis for new product development. New material/supplier development and validation. Exploring new material testing facilities and equipment with external labs and institutes. Establishing soft and hard magnet testing facilities. Preparing internal material specifications and standards. Handling metallurgy lab and creating lab manual.

Design and development of new chains to meet customer requirements. Propose appropriate product from catalogue based on 2 Wheeler customer requirement. Validation of changes in tool, new tool and process of existing products. Lead cost reduction (VA/VE) ideas in products. Spearhead failure analysis of chain products using 8D, FTA, Fish Bone diagram till implementation and validation of the change using A2B comparison. Closed 8D on SCC chain failure with Mahindra and Mahindra. Coordinate with global team on product validation.

Converting Technical requirements of customers into cost effective products. Provide technical proposal for new business opportunities. Technical review and engineering support for new product development with suppliers. Support manufacturing and quality for new product development. Lead Design cost reduction (VA/VE) ideas.

Designed and developed Electric Secondary Air Injection Valve towards meeting BS VI emission norms for TVS Motors. Allocated budget for design and development of Electric Secondary Air Injection Valve and Electric Canister Purge Valve. Handled complete design and development of REL Pressure Control Valve (PCV), TVS XL 100 carburetor, TVS Jupiter and Jupiter VE carburetor projects. Provided solutions to our suppliers with Failure and Root Cause analysis on every new product within UCAL. Involved in calibration of Electronic Carburetor to meet BS VI norms. Conducted Lectures on recent trends in Automotive materials. Spearheaded VA/VE ideas of material change from aluminum to plastic and removal of surface coating on solenoid plunger in Electric Secondary Air Injection Valve. Handled the complete design, fabrication and installation of new test rig for testing of Electric Secondary Air Injection Valve and Electric Canister Purge Valve.

Part of the R&D- New Materials team in conducting sintering trails on various blended powders for process establishment of new materials. Performed metallurgical microstructure studies and hardness testing (Vickers & Rockwell) on sintered powders. Responsible for aluminum production line with reduction in cycle time by 40%. Trained on 5S, MSA, SPC, and APQP industry standards with hands-on initiation to PPAP and SPC.

• Mixing base powders with additives in various proportions using ball milling
• Conducting sintering trails and evaluating quality for each process trials
• Establishing process parameters and recording each trials.
• Mention measurable impact or results you helped deliver. Focus on the outcome of tasks. Example: Modified customer service support system to reduce complaints by 10%.

• Reduction of number of rolling passes of Aluminium Ingots to make into flat sheet required thickness
• Evaluating and recording quality at each pass
• Wire brushing these improved sheets and bonding with steel
• Ensuring final Al-Steel Bimetal bearings quality
• Mention measurable impact or results you helped deliver. Focus on the outcome of tasks. Example: Modified customer service support system to reduce complaints by 10%.

• Design validation testing of float systems.
• failure analysis of validation test parts and correction in design and supplier process
• Reverse engineering and benchmarking competitor parts
• Vehicle testing and carburettor tuning
• Revalidation of design improved parts
• supplier handling and development of injection molding parts
• Mention measurable impact or results you helped deliver. Focus on the outcome of tasks. Example: Modified customer service support system to reduce complaints by 10%.

• Product/design validation
• trouble shooting rejections in-house and customer end
• Carburettor tuning
• Selective engine and vechile assembly and testing
• Mention measurable impact or results you helped deliver. Focus on the outcome of tasks. Example: Modified customer service support system to reduce complaints by 10%.

• BOM and supplier development
• Proof of concept
• Prototyping
• Benchmarking and reverse engineering
• Joint testing with the customer
• Recording TGR and TGW
• Drawing verification and release
• Alternate material validation and cost reduction-40%
• DVP sign off with customer
• Proto line set up and led a team of 3
• Proto parts and production part validation
• Preparing APQP and PPAP documents at each stage
• Mention measurable impact or results you helped deliver. Focus on the outcome of tasks. Example: Modified customer service support system to reduce complaints by 10%.

• Getting inputs from customers and translating them into design inputs
• Creating Budget allowance for proto build-up
• Design calculations and verifying 3D models are as per Design Guidlines
• Checking and verifying drawings before release
• Releasing drawings and getting global approval through PLM teamcenter
• Mention measurable impact or results you helped deliver. Focus on the outcome of tasks. Example: Modified customer service support system to reduce complaints by 10%.

Proton Exchange Membrane Fuel cells (PEMFC) are being explored for passenger vehicles as an alternative to bulky and CO-emitting Internal Combustion Engines. This Paper is about find a replacement for cost materials used as Anode and Cathode catalysts as well as Proton exchange membrane