Rajadurai Bakthavathchalam

Experience

• 

  SAM TURBO INDUSTRY PRIVATE LIMITED

  Sept 1989 - Dec 1998

  Methods & Development Engineer

  • Responsible for new casting development from pattern manufacturing until final customer acceptance test of radiographic quality• Developed wide range of castings for Chemical, Process, Paper, Mining, Oil & Gas Industries and Power plants • Experience in Manufacturing castings conform to ISO, IS, ASTM, JIS, AFNOR and BS standards weight ranging from few grams to up to 3Ton.• Developed composite machinable inserts for high hardness alloy castings (600BHN) for mining Industries• Participated in many Import substitution projects by developing casting through reverse engineering• Engaged in Aluminum die casting outsourcing project where we developed cast parts with internal sand cores• Developed prototype Centrifugal casting system to make wear resistant sleeve parts Show less

• 

  TEXMO INDUSTRIES - India

  Jan 1999 - Feb 2001

  Engineer

  • Responsible for Pattern shop to manufacture pattern and core boxes for automated and manual foundry Grey Iron production line• Developed tooling for Haflinger high pressure molding line and automated Lampae Core system for Pump and Motor castings• Responsible for new casting development from pattern manufacturing until final customer acceptance test• Part of quality control team and responsible for tooling Improvement to reduce the scrap and sustain the yield rate• Short-term assignment in Investment foundry department and had hands on experience of manufacturing processes Show less

• 

  SLB

  Mar 2001 - Aug 2023

  - Responsible to ensure equipment delivery on time per high volume operational demands for a most demanding customer- Improve equipment reliability for division assets as well as improve efficiency and increase asset utilization- Task to reduce cost of service delivery and own the Asset maintenance and sustaining process- Ensure the full implementation, adoption, and effectiveness of the processes to support the business and drive associate metrics- Implement and comply with maintenance programs through Computerized maintenance management system and Standard work adherence- Lead Continuous Improvement culture by developing, standardizing, and supporting CI Initiatives Show less - Responsible to deliver cost competitive products to outperform the market - Re-Think manufacturing to create Agile capacity - Digital factory road map to establish Industry 4.0 platform building blocks- Improve efficiency and productivity with Breakthrough and Flexible Manufacturing system - Alternative and cost-effective raw material to challenge the price pressure- Higher Cost/lift ESP through Innovative and new technology process- Deployment of 3D sand core printer for new gen stage development- Training and development hub to upskill local workforce Show less • Responsible for ESP Stage Product Line to manufacture and supply ESP stages to worldwide Schlumberger Artificial Segment• Manufacturing work force of 200+ and ability to produce both high mix low volume and low mix high volume product mix parts• Automated Manufacturing facility equipped with 44 Robot handling unmanned cells coupled with customized Manufacturing Technology to improve operational efficiency from increased Work Center utilization• Lean manufacturing production flow with Kanban pull system between foundry and machine shop to supply products in a shortest lead time for the flexible customer demand• Continuous Improvement through Lean tools, Six Sigma methodology and Kaizen projects to drive the Product Line manufacturing cost down• Maximizing ESP stage performance through deployment of advanced raw material and exploring alternative manufacturing process• Built stringent process control throughout the value stream to supply reliable and consistent quality stages to the field locations Show less • Responsible for manufacture and supply Wet mate and dry mate connectors for Schlumberger Subsea Segment. • Manufacturing work force of 100+ with in-house advanced moulding technology, assembly and full-fledged testing capabilities • Established Cellular manufacturing to improve mold part productivity and Deployed Mold tool management to improve the consistent quality of molded parts.• Brought the latest technology elastomer mold presses and upgraded thermoset plastic hopper loading system to improve the capability and reliability of molded parts• Revamped the manufacturing shop floor to improve material & process flow, initiated many kaizen projects to improve the manufacturing efficiency Show less • CPCB manufactures high precision, technologically advanced Flow Control Valves and Multi Port packers for the Schlumberger Completions Segment.• Vertically integrated center ability to manufacture and test completions equipments for API standards, responsible for Mfg technology deployment and Process Improvement • Machining being the critical process, Integrated Tool room and program team and Improved the First article prove out process through deployment of Edgecam software • Focused on long cycle time pat manufacturing, achieved machining cycle time reduction through Tool setter deployment and tooling improvement • Implemented Visual Lean tools on the shop to improve the material flow and Improved Machine uptime through TPM Implementation for key machines Show less • Responsible for manufacturing Down Hole Equipments to Russian Market in the newly built plant, Lead 80+ young production work force on a Lean Journey• Deployed Lean infrastructures through Employee Training, Process Stability, Continuous Improvement and brought all the functional team close to the operation to improve communication.• Established Employee owned 5s Improvements, Flexible workforce through cross departmental training, Visual workplace to make problem visible. Deployed CONWIP supermarket for finished products and FIFO production line for Assembly Line Show less • Manufacturing Engineer for ESP Stage product responsible for process control, process improvement and capital investment in foundry• Acted as Design for Manufacturing Engineer for the new stage development and part of the Concurrent life cycle management system• Handled $6M Foundry Capacity Expansion Project includes 2 furnaces and 10 other production equipments, successfully installed in 3 months with minimum disturbance to production.• Mentor and coach for Junior engineers on tooling techniques, process establishment and improvements. Conducted many Lean training and process Improvement workshops for the production team• Deployed the first robot cell in foundry casting finishing area to improve the productivity and remove the HSE risk of operator being exposure to the high-speed grinding wheels.• Deployed the first automated tooling in core machine which improved the core output by 42% and operator fatigue was eliminated by avoiding repeated tooling handling • Involved in many plant strategy presentations and discussions and provided improvement suggestions to achieve the vision goal. • Identified many cost saving opportunities and initiated cost reduction projects to keep the in-house cost competitive without compromise the quality standard Show less • Manufacturing Engineer for ESP Stage product, responsible for process control, process improvement and capital investment in foundry• Took additional responsible of Tool room operation with a work force of 7 tool makers where I was responsible to manufacture plant tooling needs.• Responsible for new stage development from scratch until product Commercialization. I have developed about 45 over new stage products in 3 years• Initiated many Lean projects to improve the value stream of the casting manufacturing inside the foundry to reduce Lead Time and product cost• Part of the Stage unit integration team where we integrated foundry and machine shop as a single department after establishing pull system between foundry and machine shop.• Lead about 7 Six Sigma Black Belt projects over 3 years and brought significant cost saving to the company. Also coached and mentor many cross-department projects.• Handled capital equipment projects, installed additional Cold box machines and Amine scrubber system to improve productivity and safety in foundry. Show less • Responsible for Process Engineering in Sand and Investment foundry manufacturing ESP Stage casting • Manufacturing capabilities includes Automatic Green Sand Molding lines, Chemical bonded mold line supported by High-end Core machines• Established consistent process and setting up bench mark standards for tooling and foundry processes when foundry was suffered with in-stable process and in-consistent quality• Lead several significant process improvement projects which were not only resulted in substantial cost savings for the Company, but also lead to reduction of scrap and cut down of non-value-added activities in the foundry operation• Instrumental in Hunter Turnkey project success by converting entire Stack mold line castings in to Green sand mold line casting• Developed over 50 new tooling with unique gating system for thin wall ductile alloy casting and reduced the scrap rate by 50% Show less

  • Technology Life Cycle Management Manager

    Apr 2022 - Aug 2023

  • Manufacturing Technology & ESP Stages Product Line Manager

    Mar 2018 - Mar 2022

  • ESP Stage Product Line Manager

    Mar 2013 - Feb 2018

  • Mfg Engineering Manager -Down Hole Equipment

    Aug 2012 - Feb 2013

  • Center Manufacturing Manager

    Aug 2010 - Jul 2012

  • Manufacturing Technology Manager

    Jul 2009 - Jul 2010

  • Production Manager-ESP

    Jul 2007 - Jun 2009

  • Senior Manufacturing Engineer

    Aug 2005 - Jun 2007

  • Manufacturing Engineer

    Mar 2004 - Jul 2005

  • Foundry Process Engineer

    Mar 2001 - Feb 2004
• 

  Cameron, a Schlumberger company

  Sept 2023 - Jan 2025

  Manufacturing Expansion and Modernization Manager

  -Responsible to build a fully automated manufacturing process flow as part of the capacity expansion-Tasked to meet growing demand through improved Productivity with consistent quality in a safe environment-Material supplied from Autonomous ware house with Automated Guided vehicle to Automated Cells-Vision aided Robot tending machining cells ,Robot Deburring Cell ,Auto washing and Inspection Cell and Auto Blasting and Painting are part of the value stream