Manoj Tanwar

Experience

• 

  Maruti Suzuki India Limited

  Jun 2011 - now

  •Responsible for design & development of new advance prototype 6MT transmission unit Gear Shift & Select system parts (sheet metal, casting & forging), TM helical gears, Lubrication system parts (Plastic). Did concept sheet preparation as per marketing inputs, QTT target setting, TM unit layout, design, overall project planning and coordination. •Prepared test Reliability sheet, Test specification SORs for WC testing and support in proto TM assembly and coordinated for proto stage bench and vehicle level evaluation. •Presentation and coordination of design reviews (Kickoff, Concept, Structure, DMDR, Drawing DR etc.) and quality gates for multiple SOP models. Responsible for localization, 2nd sourcing and VA-VE project reviews and monitoring.•Layout, CAD modeling, drawing drafting, sketching of multiple TM parts in UG-NX which included Sheet metal, Plastic, forging & machining parts. Conducting part manufacturing feasibility study, making drawings, conducting RFQs, technical reviews, quotations and sourcing coordination for new proto parts development.•Advance CAE in UG-NX for design optimization for strength and durability as per design standards. •Root cause analysis and countermeasure study for market reported issues (Gear knob vibration, synchronizer ring damage etc.), New advance design TM observations (Gear pitting, parts touching, Reverse brake mechanism, oil leakage etc.) and New TM application (Layout, Clearance check in static and dynamic condition etc. ) using tolerance stack-up analysis ( RSS & Monte Carlo) and FTA. •Coordination with cross functional teams of Quality, Service, production and testing for resolution of market issues, New design observations and Kaizens in running production parts.•Mentoring and support to team members in learning TM parts design methodology and understanding of part development cycle.•Process improvements by revising design calculation sheets as per new learnings. Show less •Project manager for Gear steel localization and alternate sourcing. Collaborated with cross functional team of production, Quality and Supply chain for indigenization of gears & shaft steel and achieved annual saving of ~ 8MnRs in first phase.•Worked on Design and development of 6MT TM for high torque E15 engine developed by Suzuki. Responsible for Vehicle level layout, parts design modifications and VE-VE in-line with local supplier capabilities, reliability sheet, Design-testing coordination, Model trials (DP, PP, and MPP stages), Hinkai resolutions and successful model linking.•Design and development of shift tower parts by application engineering for Suzuki carry model.•Root cause analysis, tolerance stack checks, study countermeasure proposals and implementation done for critical market and development problems. Reduction in market claims lead to total annual saving of ~ 33MnRs.•Compiled and implemented VA-VE improvement ideas by performing teardown benchmarking and Kaizens for current TM parts by following cost and value centric approach, achieving total annual cost saving of ~ 51MnRs.•Did gear shift feeling improvement project in running TM used for K15 engine application by modifying shift system parts with weight reduction and minimum cost impact.•Mentoring of new team members for shift system parts design and development. Also responsible for new GET orientations.•Process improvement by recording design change history in TM parts for making ECN tracking summary sheet along with SMC team.•Documentation and compilation of technical design reports, assembly check sheets and design database for benchmarking. Supported Intellectual property rights (IPR) team in preparing design comparison sheet and novelty search report for filing patents. Show less •Responsible for localization and development of TM parts for FR vehicle. Changes done in parts CAD model & drawings for local manufacturing, float control and design improvements. •CAD modeling, design calculations and drawing preparation for gear shifting system sheet metal parts of compact 5MT TM. Work included CAD modeling, Layout check, Tolerance stack-up, CAE analysis, Design calculations, Drawing making, Part development and testing coordination.•Completed task of major design improvements in high selling existing TM series for parts strength, gear shift performance, market quality issues, efficiency and oil churning loss improvement. Worked on design of synchronizer system, bearings, lubrication, breather and gear shifting mechanism.•Development and sourcing of alternate source parts for supplier risk mitigation by conducting technical reviews, Specification meetings with Supplier, Quality and supply chain teams. •Tolerance stack-up analysis for touching issues observed in Shift system parts reported as gear hard shift issue. Show less •Prepared CAD model and drawings for gear shifting system of 5MT TM. Verification and improvement in design by tolerance stack-up analysis, CAE simulation for strength and deflection.•Developed shift system parts for gear shift feeling improvement project used for manual transmission application in diesel vehicles. Support in evaluation, failure root cause analysis and countermeasure action.•Responsible for alternate sourcing, VA-VE and localization projects for existing TM parts which included sheet metal parts, fasteners, circlip and washers. Show less

  • Manager,Transmission design and development

    Apr 2019 - now

  • Deputy Manager, Transmission design & development

    Apr 2015 - Mar 2019

  • Assistant Manager, Transmission design & development

    Apr 2012 - Mar 2015

  • Graduate Engineer, Transmission Design and Development

    Jun 2011 - Mar 2012