Santhosh Vijayan

Experience

• 

  Bajaj Auto Ltd

  Jun 2003 - now

  Leadership benchmarks• Led the successful completion of design projects for a range of Bajaj and KTM vehicle models• Successful Brand Manager – Successfully led design projects for Pulsar 200 NS and Dominar 400 models while overseeing all aspects of the product development process, including brand attributes, product attributes, positioning, design, validation, and production readiness• Holds the merit of developing: o Cutting-edge engine/vehicle subsystems, like DOHC power Train and cooling system, established new benchmarks in performance, efficiency, and reliability for Bajaj models. o Improved the design and analysis methods of various engine and vehicle systems, incorporating novel approaches and techniques to achieve superior performance, quality, and cost-effectiveness. o Developed and implemented a matrix structure for subsystems in Bajaj R&D, focusing on valuing and updating skills, fostering creativity, advancing technology development and knowledge capture, and enhancing team motivation.o Pulsar 200NS for the Philippines and Thailand market through collaborative engine design and validation with Kawasaki R&D Department • Played a major role in carrying out the technical feasibility study and business impact analysis of KTM designs and redesigned them to suit the Indian manufacturing process• Establishing region/country-specific durability cycle for BAL/KTM models.• Handled the knowledge transfer process from KTM Austria R&D.• Track record of success in.o Conducting CFT visits to international markets like Colombia and Dubai and domestic markets to understand the impact of environmental factors, driving style, and maintenance/service procedure on durability and quality issueso Served as a part of CFT audits at Domestic and Abroad Vendors (China and Taiwan) – ensuring design, production capability, and quality adherence of power train partso Steered value engineering initiatives to optimize cost-benefit ratios in key automotive subsystems Show less • Implementing Six Sigma methodology in design by identifying and measuring critical-to-quality characteristics of the product and process.• Working on multiple BAJAJ / KTM projects requiring conceptualization of design, detailed layout, supporting analysis, DFMEA/DFM/DFA/DFS, development, validation, and production implementation• Facilitating design review activities in collaboration with project management, manufacturing engineering, and component development teams to ensure the timely development of automotive parts that meet technical and commercial targets.• Hold ownership of the cost per piece, quality, aesthetics, and functionality of the design• Understanding, conceptualizing, and crafting product features and attributes through user experience study on motorcycle models.• Resolving quality issues and improving validation cycles for automotive components, focusing on area/country-specific requirements. • Managed end-to-end engine development activities for multiple models, including basic layout, cost-benefit analysis, prioritization, detailed design, and release, resulting in successful product launches.• Liaised with cross-functional departments like manufacturing, production, component development, testing, homologation, and service support• Captured and specified the design and validation requirements to deliver successful systems, products, and components to meet/exceed the customer's expectations.• Communicated regular progress updates on design, costs, and manufacturing challenges to CTO and VP R&D• Managing employee performance and team-building activities, identifying issues, suggesting training, working practices, and process changes. Show less • Led Bajaj Kristal's Continuously Variable Transmission (CVT) system development, including torque and speed mathematical modeling, simulation, and fine-tuning to ensure a smooth and responsive driving experience. Managed the CVT system development process and developed the IVT (intelligent variable transmission) logic and prototype.• Accountable for the design and analysis of various mechanical subsystems. Built and validated test rigs to verify simulation results.• Performed linear static and topology optimization for engine parts- optimizing engine parts for light weight, strength, and modes.• Performance prediction for Pulsar and Kristal's engines using advanced software tools such as Ricardo WAVE and valve train optimization using Valkin/Valdyn. Developing a novel oval beehive dual-rate spring was a first for the organization.• Optimisation of engine parts for performance, cost, and NVH.• Manufacturing process optimization/line setting for crankcases and cylinder heads entails selecting suitable manufacturing methods and optimizing production processes to ensure high-quality, cost-effective production. Show less

  • Division Manager

    Jun 2018 - now

  • Bajaj Auto Ltd. | Vertical Lead Engineer

    Jun 2009 - Jun 2018

  • Bajaj Auto Ltd. | Assistant Manager

    Jun 2003 - Jun 2009