Neeraj Vijayan

Experience

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  Tesco

  Jan 2010 - Jan 2012

  Stock Control Assistant
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  IKSC Knowledge Bridge Pvt. Ltd.

  Jan 2012 - Dec 2012

  Product Design Trainee

  ● Worked on a Speed Reduction Gearbox for Tier-3 Supplier

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  L&T Technology Services Limited

  Dec 2012 - Mar 2014

  Product Design Engineer-Skid Steer Loaders/Wheel Loaders

  ● Re-designed metallic Rear Hood, Air Intake Hose, Fan Covers, Floor Pads and Side Consoles for all variants of SSL/Wheel Loader to Non-Metallic versions to lower cost & weight and augment Assembly/Serviceability. • Conceived new Casting designs for Counterweights for Skid Steers and Alternator Mountings that rectified form & fit issues during Tier-IV Upgrades for 721/821/921 Series Wheel Loaders. ● Helped lower machine cost by 8% by simplifying Hydraulic Routing for the Transmission Hoses and Tubes and managed the accompanying changes to Chassis and boom assemblies across all Skid Steer/Wheel Loader variants. Show less

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  CNH Industrial

  Mar 2014 - Jan 2016

  Senior Design Engineer-Vibratory Compactors

  ● Worked as Machine Integrator for all Vibratory Compactor Products & variants by maintaining Machine BOM, Machine Saleable Mass, Machine CG, etc and conducting regular Virtual Design Review Audits (VDRA). • Pioneered dual-compatible large-volume plastic Water Tanks, ergonomic steering console/driver control systems, and aerodynamic Canopy Roof for 752 EX Compactor, with thorough Supplier & cross-functional team collaboration; resolved issues during Prototyping and Pilot build stage to bring parts into Production. • Designed & developed Side & Front Steering/Driver Control Console Unit, and Moulded Headliners for 1107DX & 1107EX Canopy & Cab variants with near-zero defects and rejections. • Re-modelled Access Systems like Sheet Metal Doors and Covers to satisfy ISO 2860, 2867 Ingress/Egress goals for 752EX Compactor. • Used acoustic insulations for Cabs to attenuate Operator Sound to meet Industry Standards. • Participated in multiple Benchmarking exercises to help derive Product Requirements. Show less

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  Caterpillar Inc.

  Jan 2016 - Jul 2023

  ● Design Team Lead & Configurator role for all Surface Rock Drill & Hydraulic Mining Shovel Cabs. ● Managed a 5-member team to complete first-time in-house Electrified Cab Design & development for use in MD6640 Electric Drill that reduced system cost by 50% and created savings of $200,000/machine versus Legacy Design. ● Led a 4-member team to design and develop the first fully Electrified Operator Cabin for 6060 Hydraulic Mining Shovels, with a modular HVAC strategy and Structural re-design, thereby decreasing Cab cost by 10%. ● Employed DMAIC to monitor, root-cause, resolve and develop corrective actions for multiple field-failures & performance problems, thereby reducing customer warranty claims by up to $1 million for the enterprise. ● Released Retrofitted Offerings for Displays, Seats, Machine Autonomy and HVAC Performance Improvement for Drills & Shovels. ● Initiated business cases that helped see rise in overall APQP Conformance to 95%; Conducted training sessions for the Cab team in DFMEA and Built-In-Quality that improved quality metrics to 97% and helped drive towards a defect-free culture. Show less ● Assisted with Cab Build, Issue resolution & EOL Testing for multiple Drills.● Developed and validated Small Rock Drill MD6200 FOPS Cabin program from ground up in span of 8 months, achieving 13% cost savings.● Performed Ergonomics reviews per ISO 6682 & ISO 3411 that helped improve Operator Comfort level during machine operation, enhanced reachability to controls, switches, joysticks, control pedals, etc.● Boosted Aftermarket sales for Legacy Cab parts by correctly converting 3-D geometry, eliminating duplicate part numbers, and ensuring correct branding & Supplier sign-off. Show less ● Overhauled FOPS Cabin for MD6250, MD6310 and MD6380 Surface Rock Drill Machines with fixture-less modular design that improved Operator Comfort, certified ISO 3449, and reduced cost by over 30%.● Expanded Operator Visibility by 18% using Creo/VizMockup for multiple Drills, Excavators & Trucks by adding visibility aids (mirrors, cameras, etc) in conformance with ISO 5006 & ISO 14401. ● Designed roto-moulded HVAC ducts for different Cabs that doubled HVAC performance and Operator Comfort. ● Worked on ROPS structure design of 5050, 5075 and 5150C Track Drill programs to reduce costs by 15%. Show less

  • Team Lead - Cabin Design (Surface Rock Drills & Hydraulic Mining Shovels)

    May 2022 - Jul 2023

  • Senior Cab Design Engineer-Surface Rock Drills

    Jun 2019 - May 2022

  • Cab Design Engineer-Surface Rock Drills/Trucks

    Jan 2016 - Jun 2019
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  JCB

  Aug 2023 - now

  Engineering Team Lead/Lead Design Engineer - Cab Design

  Lead for Mini/Compact Excavator Cab Design