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David Raj G

Manager Manufacturing Engineering Managerial assignments in Manufacturing Engineering / New Projects in Automotive Paint shop, Body shop with an organization of high repute

Work experience


Nov 2014Present

Lead Engineer Manufacturing & New Projects


Responsible for new projects & Manufacturing Engineering

  • Heading new projects: Handling various department as a core team members cross cultural team (including central industrial Engineering team Europe/Asian reagion)
  • Responsible for setup manufacturing facility, process including capital equipment installation, Commissioning and Validation activities. For new products and capacity improvement activity
  • Planning and realization of new products, stamping welding installing Assembly line and press Machine, shop line layout and Painting process
  • Lead the projects from Design to installation, Manage project schedules, Testing and meeting the allotted budget for the project.


Key responsible area :

  • Heading new projects: Handling various department as a core team members cross cultural team (including central industrial Engineering team Europe/Asian region)
  • Provide leadership and direction to multi-function teams to product development strategy and control all functions involved in the product development process. Ensure the new projects and products program meets all goal requirements for product function and reliability, program cost/budget
  • Lead new projects teams in new model development and introduction plans; establish performance, quality, cost, and investment targets. Responsibilities of the NPI teams are to establish and achieve target costs; establish and achieve reliability targets, establish and achieve time frame, execute the technical specifications; shorten resolution time, achieve manufacturability, assure process conformance; and determine, justify and monitor capital investments.
  • Ensure all technical, cost, marketing, manufacturing, materials, and test & evaluation problems are addressed and solved. Investigate alternatives and solutions and assign appropriate resources to execute resolution plans.
  • Develop teamwork breakdown structures, project workbench activities and additional control systems. Develop test plans based on risk assessment and reviews all research, engineering, test & development and marketing plans to ensure successful product introductions
  • Ensure the development and training of team members. Communicate and coordinate activities

Actively participate in all decisions for NPI concept, design, build & test, release and production


Jun 2011Nov 2014

Manager Manufacturing Engineering Paint shop


Bharat Benz, Fuso, Mercedes Benz- trucks paint shop

  • Planning and Realization of paint shop equipment's, planning and execution of New paint shop building and paint booths as per the time plan -Handled capex value of Project value 140 core INR for cab 2C2B process
  • Planning and realization of material handling system for complete paint shop 2 km for 6.02 min ,4.15 min,3.14 min Tact time plans
  • Planning and realization of Suitable skids, jigs and fixtures for all variant cabs
  • Conducted station development work shops ,Training production teams ,improving operation skill level to achieve tact time Manual work station(PT&ED, ,topcoat  ,repairing PBS and CIW loading stations)
  • RFQ preparation, supplier selection, techno commercial interaction with suppliers for paint shop
  • Planning and realization of spare part manufacturing process for produce 5% spare of overall production volume at new paint shop
  • Responsible for capacity improvement planning


Bharat Benz, Mercedes Benz- Bus Project.

  • Planning and Realization of paint shop equipment's & material handling equipment's for bus chassis painting process



Aug 2008Jun 2011

Manager (body in white projects & automotive painting )

  • Planning, Installation and commissioning of robot system for Automobile projects
  • Manufacturing and assembly of jigs and fixtures for automobile body components
  • Responsible for incoming quality of jig components, Assembly of jigs and fixtures for robot cells
  • Responsible for assembly of fixtures and integration of robot cell in house & customer end
  • Responsible for installation planning and Engineers deputation as to achieve the time target
  • Responsible for buy off process and project completion project.


  • TATA                      (Jamshedpur) -   World Truck (off site- with robots)
  • Ford India               (Chennai)      -    Ford Figo   (closures robot roller hemming)
  • Mahindra & Mahindra (Nasik)    -    Mahindra Xylo (closures robot roller hemming)
  • Mahindra & Mahindra (Pune)   -      Xylo Pick up (U202) (closures robot roller hemming)


Jun 2005Aug 2008

Engineer Automotive projects


- Expertise & Responsible for layout marking and installation of robots for complete automated car body weld shop

- Responsible for conveyor and material handling system fabrication and installation

- Expertise in paint shop projects paint booth fabrication and paint robot base frame fabrication and installation

- Responsible for Car assembly shop projects like conveyor system installation and commissioning


  • Hyundai Motor -Sriperembdur      Phase 2 Body Shop (275 numbers Robot Installation & manual work station)                                                                                                                
  • Hyundai Motor - Sriperembdur     Phase 2 Assembly shop Conveyor installation Clint Dongroofa Korea
  • Hyundai Motor - Sriperembdur        Phase 2 Assembly shop lighting system installation Clint Wampfler energy
  • TATA Motors -Singur Kolkata        TATA Nano (SMAL Car Project) Assembly Shop Clint Hyundai heavy industries
  • Hyundai Motor -Sriperembdur      PDI shop Structural fabrication and Erection client AMCO construction Korea
  • Hyundai Motor -Sriperembdur      Repair shop structural fabrication and Erection client AMCO construction Korea
  • Hyundai Motor -Sriperembdur       Test track service building client AMCO construction Korea
  • Hyundai Motor -Sriperembdur        Engine shop building construction (mechanical part) Hydong Engineering Korea
  • Hawashine Automotive               Small part paint shop (electro deposition type) Clint Jintech Engineering

ASHOK LEYLAND - Foundry Division

Sep-2016Til Date

Manager Projects



Apr 2001Apr 2005


2005; Scored  70%

pallavan polytechinic

Apr 1998Apr 2001

Diploma in Automobile Engineering

2001 : scored 90 %


CAD Packages                                  AutoCAD2008, Solid Works

ROBOT simulation                          Robot studio 12.4 (ABB Software)

Robot programming                        Robot studio, teach pendent                                

Platforms                                      MS- Office, MS word, excel

A result oriented professional with over 10 years of proven success in world leading Automotive industry in Operation and manufacturing Engineering

Expertise & Responsible for design and delivery of various processes for automotive lines body welding and painting

Paint shop: paint shops planning, design, manufacturing & installation of paint shop according to process requirement, specialist in Conveyers Systems for paint shop & complete material handling system for paint

Body shop: body line building and robot system building, jigs and fixtures for Car & truck Body Parts, having hands on experience in installation and commissioning of robots more than 300 robots( ABB, YASKAWA, HYUNDAI ROBOTS) Jigs and Fixtures,

An effective communicator with excellent relationship building & interpersonal skills. Strong analytical, problem solving & organizational abilities. Possess a flexible & detail oriented attitude.

Area of Expertise

Manufacturing Engineering: Managing the projects from concept to commissioning stage & handling project activities involving working out various requirements with respect to planning, utilities, machines, manpower & monitoring overall project execution for ensuring timely completion. Managing project activity manufacture of conducting meeting with customer and channel partners and vendors.

New Product Development: Understanding overall operations for new products or improvement of existing products with thrust on reducing product cost. And optimizing the existing line to adapt the new variant to reduce large investment and time

New variant study: Conducting new variant study and generating investment plane for new variant. Recommending process modification for R&D, Recommending man power requirement for production to achieve cycle, tact time at process.

Installation and Commissioning: Having rich experience in installation & commissioning of Paint shop, body shop Pre Treatment and Electro coating lines, ED sanding ,Sealer application line ,Top Coat line, major repair, Wax application line for car & Truck paint shop   ,Robot and robot cells integration for complete body shop conveyor system for booth body and paint shop

Construction: having a experience in construction of plant, strong knowledge in fabrication and erection of structure, column, roofing, utility, arrangements facility requirements for manufacturing shops


Tool Room Operations: Handling new product components development, tools trails outs, modifications & implementation in method planning to fulfill requirements in line with company & customer requirement. Ascertaining requirements of programming &development of Jigs & Fixtures new processes for manufacturing components for smooth production.


Date of Birth           : 18th August 1982

Languages               : English, Tamil & Hindi

Address                   : No. 18, Koothavakkam Village Sriperembdur Taluk,

                                 Kanchipuram District-631 553,

                                 Tamil Nadu, India