Vijayakumar S

Experience

• 

  Sundaram Clayton Limited

  Apr 2008 - Jul 2014

  As the Process Incharge for Volvo, Daimler & Cummins parts, I’ve managed a team of 4 junior engineers working on the process.Monitoring the quality of castings produced on 4 HPDC machines (3200T, 2700T-2, 1350T).Process parameter design & setup for new mold.Spray tool design & process optimization for new mold.Defect analysis.Action plan development & implementation.Trail execution & DOE.Result monitoring & Standardisation.Training of the engineers & the operators. Show less I’m part of a team of 10 process specialists and engineers.Monitoring the quality of castings produced throughout the plant (50+ HPDC machines).Prioritising & defining the problem (data collection & analysis).Defect analysis (characterisation by destructive & NDT, Various problem solving tools).Action plan development & implementation.Trial execution & DOE.Result monitoring & Standardization.Process parameters optimization & monitoring.Die temperature optimization & monitoring. Show less Managed over 30 operators & technicians.Responsible for production & quality of parts produced on 4 HPDC machines (3200T, 2700T, 1350T, 800T).Responsible for the delivery of castings to the machine shop after finishing (Deburring, shot blasting).Control the cost of the foundry consumables(die lub, aluminium oxide, steel shots, etc.,).Process & DCM cell troubleshooting.Die changeover & process set-up.Maintaining the 5S.Facilitation of a QCC team (focus on improving safety, quality, productivity, availability & cost).Member of a CFT.Hourly production & quality monitoring.Responsible for the OEE of the 4 HPDC machines on my shift.Training of technicians. Show less

  • HPDC Process Incharge- Volvo, Daimler & Cummins parts

    Apr 2012 - Jul 2014

  • HPDC Process Engineer - Special Task Force

    Apr 2010 - Mar 2012

  • HPDC Production Supervisor - Volvo, Cummins, Hyundai parts

    Apr 2008 - Mar 2010
• 

  Ashley Alteams India Limited

  Aug 2014 - Dec 2016

  Senior Engineer- Casting ME

  Responsible for the entire automation of the HPDC shop(Purchase, installation, Programming & optimization of Extractor, Sprayer, Robot, Spray & Trimming tool, Grippers).Productivity improvement(adoption of new technologies, optimization of the process & the equipment).SMED(reduction of mold set-up time).Leading a task force to improve the Quality of complex casting(QC Story). Support for the implementation of TPM.

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  India Yamaha Motor Pvt. Ltd.

  Jan 2017 - Jul 2018

  Assistant Manager- Casting ME

  Responsible for designing the process (Machine locking force, Orientation, Parting line, Gating & Exhaust layout, CAE evaluation, Design & Process FMEA, Control plan).Mold manufacturing (Design review, Raw material, 2D Dwg, Balloon Dwg, Manufacturing follow-up, Trial, Inspection, dimensional proving, file & spares).Casting process proving (Process calculations &Setup, DCM & Peripherals programming, Die temperature optimization, Cycle time optimization, part integrity proveout).Jigs & Fixture design, manufacturing, proving (Spray tool, Deburring jigs, Degating jigs, Shakeout, Inspection jigs, Trolly & Pallet).Preparation of the process standards (Process parameters, CQC, Spray map, Die temperature map, Degatting, Deburring, Final inspection, Material handling, Heat treatment, Process flow, QCPC, PPAP).Commissioning of new machines.Duplicate mold & Core box manufacturing.Critical die spares & mold maintenance.Implementation of Innovative technology in casting process to improve Safety, Quality & Productivity. Leading a Task force & QCC team.Training of technicians.J1+90 Support. Show less

• 

  Ford Motor Company

  Aug 2018 - now

  Conducting manufacturing feasibility study for Unicastings (Giga or Mega casting) it includes Concept runner & exhaust layout, Die vs Giga press suitability, Shot end performance of the machine (PQ^2), Part integration & filling, solidification analysis.Unicasting process design & Giga press cell configurationConducting filling & solidification analysis for the new power train and BEV components (Motor housing, Gear box housing, End cover).Evaluating the gating & process design of supplier and recommending the necessary modifications. Show less Reporting the status of the New Model Launch of Complex Casting process(NMLCC).Providing technical support to Component Program Module Teams (CPMT’s).Coordinating casting design between PD, PTME -Machining & external casting suppliers to assure design for manufacturing feasibility of new Powertrain castings.Supporting new model program cost studies.Supporting feasibility engineering studies.Supporting supplier selection evaluation process through manufacturing assessments.Providing support for casting prototype planning.Supporting PD in the selection and specification of component material & test procedures.Assisting Ford manufacturing plants as required in resolving significant engineering issues.Providing technical support as required to Purchasing(Buyers & STA) involving the resolution of casting related productivity and quality issues. Show less

  • Casting Process & CAE Specialist - Global ME

    Jan 2021 - now

  • Casting Specialist- Asia Pacific PTME

    Aug 2018 - Dec 2020