1. 1 | R a m a c h a n d r a n K
RAMACHANDRAN K INDIA | Contact: +91 98406 77093| Email: kumarara2@rediffmail.com
PRODUCT DESIGN & DEVELOPMENT PROFESSIONAL
Over 16 years of experience in:
- Product Design - Product Service - Cost Reduction
- Machine Integration - Technical Support - Project Co-ordination
- Steering and Suspension - Training & Development - Dealer / Team Management
- Structural and Hydraulics - Problem Solving And Issue
Resolution
- New Product Introduction
 PROFILE SUMMARY
 Product Design and Development Specialist with 15+ years of experience in the automotive industry, of which
13+ years have been with globally renowned industrial giant Caterpillar India Private Limited.
 Proficient in end-to-end NPI (New Product Introduction) from installation, commissioning to quality
testing, inspections, audits and compliances across various product ranges and categories.
 Well versed with the entire build-up stage of Off-Highway trucks – from sub assembly, line assembly, indexing,
quality gate inspection, functional testing, and painting and final shipment clearances from the plant/factory.
 Product Categories include Off Highway Trucks (40/50/60/100 Tons), Large Wheel Loader, Motor
Graders, Wheel Tractor Scrapers, Forest Machines, Track type Tractors and Large Mining Trucks.
 Ensures compliance with safety and quality regulatory norms and guidelines. Skilled in conducting OHT final
inspections and performance tests, manufacturing process sequence, complex conversion projects, welding
symbols and defects, GD&T and industry best engineering standards.
 Provides technical SME (Subject Matter Expertise) to machine integration, structures, hydraulics,
light fabrication, cabin, Casting, virtual design reviews and product service.
 Certified Six Sigma Green Belt professional with track record of generating cost savings through implementation
of various six sigma process improvements.
 Exposure to various other management and administrative functions such as SCM, logistics,
warehousing, manufacturing, product support, indirect purchase, marketing and dealer
management.
 Trained and mentored team members on a regular basis; engage in performance appraisals, conflict resolutions,
team building and governance activities.
 Equipped with excellent communication skills and expertise in building harmonious relationships with staff,
personnel and other stakeholders.
 Impressive career driven by a desire to be successful in all endeavours; an effective communicator with
exceptional analytical and people skills with the ability to relate to people at any level of business and
management.
 CAREER PROGRESSION
CATERPILLAR INDIA PRIVATE LIMITED Oct 03 to Aug 16
Product Service Engineer – Global Mining Division (Jun 16 – Aug 16)
Key Highlights:
 Facilitating NPI phase transformation to current product stage as a core member of the 1st production build-up.
Accountable for ensuring all field issues are resolved permanently in the 1st production build-up phase itself.
 Served as Pre-Delivery Auditor for Pilot trucks - Identified 100+ issues and ensured speedy resolution of the same
in line with quality guidelines.
 Resolved 200+ field issues in coordination with the dealers and in-house teams.
Responsibilities:
 End-to-end responsibility of commissioning, installation and testing activities for NPI Off – Highway Trucks (60
Tons / 100 Tons), along with preventive maintenance, field issue resolutions, dealer management, and training &
development.
 Engaged in complete product servicing NPI lifecycle from shipment to installation, commissioning, testing,
validation and dismantling of the truck vehicles at the various mining sites.
 Acted as Engine, Cabin and Line Assembly Coordinator and Issue Resolver for all Pilot machines.
Quality & Compliances
 Steered efforts to ensure optimal compliance of the pilot trucks with health and quality norms through
maintenance and other similar activities. Performing regular mine on-site visits to conduct inspections.

2. 2 | R a m a c h a n d r a n K
 Developed extensive coordination with the dealers and built-in synergy amongst the internal teams to ensure
quick and “first-time-correct” resolution of filed issues.
Training & Development
 Trained and mentored nearly 70+ Operators and Dealers on new truck features and functions; bridged gap
between performance and skills.
Additional Responsibility
 Identified critical, maintenance and major component parts list for the dealer stock for OMM Publications.
Lead Engineer – Product Design and Development – Global Mining Division (Feb 10 – May 15)
Key Highlights:
 Designed Steering Lock for Off-Highway trucks which was approved by DGMS (Directorate General Mine Safety)
and filed for patent with the Indian government.
 Generated savings of USD 6,000/truck (60 Tons) and USD 10,000/truck (100 Ton) by developing local radial tire
supplier for the Growth market. The Growth Market yields USD 21,000/truck.
 Standardized and established RSSM process; saved USD 1 Million by salvaging the components
 Provided engineering support to Product Build in the shop floor on OHT Assembly Line Balancing and achieved the
set through put time on each workstation of multi mix model for 777D/773E/772G&770G.
Responsibilities:
 Developed and maintained integrity of Off-Highway truck Pro/E Geometry including concept configuration
drawings, JT files, global coordinate systems, final machine configuration models, deviation approvals, field issue
resolution and more.
 Liaised and coordinated with various internal departments and teams to ensure 100% integrity of the form, fit
and function of the machine. Ensured consistency in modelling practices and design implementation.
Designing Excellence
 Strategized to enhance and grow the SOE business; created conceptual design aimed at developing 60 Ton truck
from a 50 Ton truck.
 Engaged in accredited lab testing, field trials and production implementation activities for designing of Steering
Lock for Off-Highway trucks. Ensured compliance with DGMS regulatory norms.
 Designed and developed hydraulic components such as hoses, tubes, fittings and accessories for 773E machine
builds at TOSNO plant in Russia. Generated cost savings to the tune of USD 2,200/truck.
 Strategized on designing and simplified hydraulic routing and eliminated parts quantity leading to cost savings of
USD 255/truck (770G/772G).
 Steered efforts to close the CI Cards under short/long term issues within 30/90 days. Submitted design related
issues to the DCC site and collaborated with design teams for ICA and PCA.
Technical Support Excellence
 Led the tire validation drive in India successfully for the State owned enterprise tender business.
 Guided the team on design, fitment and validation for Off-highway trucks including special instruction release for
field machines and optional attachments such as VIMS, RAC, TPMS, Fog Lamp and Auto Lubrication.
 Led Front and Rear Suspension localization for 773E and 777D Trucks.
 Served as Model Check Manager for 5 NPI Programs and resolved team center engineering issues/queries while
ensuring zero impact on NPI timeline and regular production lifecycle.
 Provided technical advisory and consultancy at design reviews and facilitated design validation and
implementation. Drove stock dispositions and directly contributed to OPACC.
Projects Undertaken
 Project Lead for 773E Mini NPI truck implementation in Russia; engaged in BOM configuration, material
availability, parts requirement, sub assembly and line assembly trouble shooting.
 Helmed Six Sigma Green Belt project on utilization of non-moving parts (> 1 year) leading to savings of nearly
USD 0.46 Million.
 Spearheaded 2 separate CPI projects on Auto Lubrication leading to reduced warranty costs.
Training & Development
 Delivered multiple training programs on Cat Vs Competitor machines and on Optional Attachment Functionality
and RSSM.

3. 3 | R a m a c h a n d r a n K
Design Engineer – Engineering Design Center, India (Oct 03 – Feb 10)
Key Highlights:
 Modelled and detailed nearly 1,000+ high quality drawings and ensured delivery within client defined timelines.
 Received appreciation from process partner for modelling and detailing of Lubricant Group for Wheel Tractor and
Scrapers (RM726, RM727, 60T, 70T, 100T Trucks) which subsequently led to continuous projects.
 Served as a Liaison Engineer in USA for 6 months
Responsibilities:
 Performed designing, modelling, and detailing of structures, hydraulic lines, sheet metal and conducted virtual
audit reviews for Wheel Tractor Scrapers, Off-Highway Trucks and Motor Graders.
 Led a 12 member’s team comprising of Service Engineers for virtual designing, detailing, modelling and validation.
Helmed administrative duties such as preparation of daily workloads and allocation of same.
Technical Expertise
 Engaged in Virtual/Pro-weld Audits, interference checking, fit-up issue resolutions, safety and service audits for
Track Type Tractors, Excavators, FM Log Loader, Wheel Tractor Scraper, LMT Truck and more.
 Technical expertise comprised of domains such as Pro/E fluid lines, top down modelling, background drawing,
interference checking, pro weld, and safety and service audits.
 Served as Engineering Change Request Resolver and engaged in modelling and detailing of various sheet metal
components and hydraulic lines.
 Prepared designs, models and conducted pro-mechanical analysis of wheel filler bencher gather arm for Wheel
Loaders to be used in forestry products and hydraulic line routing for brakes in Wheel Tractor Scrapers.
Audits
 Conducted virtual audit reviews for Monarch Motor Graders and Titan Trucks Hydraulic Hardware.
 Performed Pro-Weld Audits for D8 TTT Radiator Guards.
Training & Development
 Conducted multiple training workshops and programs on Creo, Pro/E fluid lines, Top down modelling and
Team centre Visview mock-ups.
AD TECHNOLOGIES Oct 02 to Oct 03
CAD Designer
Responsibilities:
 Profile included modelling and detailing of various automobile components, reverse engineering, pro-mold & die
casting, casting, core cavity splitting and more.
 Used Unigraphics V18 & NX, Solid Works and CATIA V5.
AXIS INFOTECH Mar 02 to Oct 02
CAD Designer – Deputed to TCS - CAD/CAM Division
Responsibilities:
 Engaged in British Engineering Aerospace Modelling and detailing of Airbus 300/640 comprising of aircraft galleys,
routing of electrical and water lines and creation of BOMs using Unigraphics V18.
 Involved in a GE project which included modelling and detailing of rotors using Unigraphics V18.
 PREVIOUS ASSIGNMENT
 Maintenance Dept  Govt. Central Press Mar 00 to Feb 01
 Quality Engineer  PL.A Engineering works Jun 98 to May 99
 CERTIFICATES / DIPLOMAS
 2007 Six Sigma – DMAIC Certified Green Belt
 2002 Diploma in Railway Engineering (65%) - The Institute of Permanent Way, India
 1998 Diploma in Mechanical Engineering (84.6%) – Directorate of Technical Education, Tamil Nadu
 EDUCATION
 2015 Master’s in Engineering – Computer Aided Design (CGPA – 7.24), Sathyabama University
 2011 Master’s in Business Administration – Product Engineering Mgmt (CGPA –6.51), Anna University
 2008 Bachelor of Mechanical Engineering (CGPA –8.43), Dr MGR Educational and Research Institute.