Objective of application: Seeking middle management level position
in Design & Development function of a professionally managed
Mohanraj Karuppusamy
Mobile no: +91 9944220935
Email: mohanraj2ker@gmail.com
Linkedin profile:
linkedin.com/in/mohanraj-karuppu
samy-2a467027
Job target:
Manager-Design and Development
/ Product development manager /
Technical manager/Engineering
manager
Basic information:
DOB: 17 Jan 1979
Marital status: Unmarried
Native place: Coimbatore dist.,
India
Languages: Tamil, English,Hindi
Profile overview:
Highest qualification: ME
Last job: Associate Tech manager,
HCL Technologies Ltd
Max. No. of reportees :
6 engineers in design function
40 workmen in production
Notice period: 15 days
Experience:
Total : 16 years 10 months
Mechanical Design and
development - Approx. 12 years
Manufacturing - Approx. 5 years
MNC exposure : Available
Abroad Travel : Switzerland, UK
Passport validity: Until 2025
Skills:
Softwares/Tools:
Unigraphics Nx1 to Nx8
- 6 years (5000+ Hrs) - Proficient
CATIA - Trained
Solidworks - Beginner
SAP-PLM, ECtr- Proficient
Teamcenter - Moderate
MS - Office - Proficient
Design & Development:
Worked in 2 NPD projects for the
full PDLC.
organization which adds up value to my career by offering
challenging assignments, learning and career growth opportunities.
Ambition: To get expertise in robust design of Electro-mechanical
products and lean development and to emerge as an independent
consultant by 2025
Educational profile:
DME (1997) - Ist class with distinction - 88.6% at Nachimuthu
Polytechnic, Pollachi, Tamilnadu, India
BE - Mechanical (2000) - Ist class - 71.1%, at AAMEC,
Bharathidasan university, Tamilnadu, India
ME - Product design & development (2017) - Ist class with
distinction - CGPA - 8.51 at College of Engg, Anna university., India
Major areas of experience:
 NPD / Product subsystem level design and development
 FMEA/DFMA/QFD/GD&T/Tolerance stackup/Calculations
 Cost reduction / VAVE/ Localisation / Standardisation projects
 Design verification testing /Automated test rig design, testing
 Design and drawings review (About 1500 drawings)
 Project /Operations/Quality management
 New project proposals / Business case / Cost-benefit analysis
 Supplier/Service provider development
 Process planning, Tool planning, Machine shop production.
 ISO 9001 - Internal auditing
 Process/templates development for Design / Manufacturing
Achievements and awards:
 Lead cost reduction initiatives and proposed cost reduction
through design change worth 800 k USD at HCL.
 Developed 7 automated/semi automated test rigs first time right
at HCL. (Project revenue: 450k USD)
 Owned project proposals worth 3 million USD at HCL.
 Submitted two new business leads and got appreciated.
 Implemented cost effective solutions in test rig design,
developed new templates and process for Design verification
testing and was awarded with R&R certificate.
 Submitted two papers at HCL on “Transforming requirements
into test rig concept” and “ROI estimation for new projects”
 Cost reduction solutions worth 40 INR/Spindle of a Ring
spinning machine at Rieter India.
 Cost reduction in tooling worth 50k INR/Month at LALW.
 Handled a major tooling up project worth 50 Lakhs at LALW.
 Published a paper in international journal as a part of ME course.
Personal qualities:
 Creative designer with strong analytical & logical reasoning,
problem solving and organizational abilities.
 Have trust in systematic working and continual improvement
 Believe “work hard but smart”
 Have an eye for detail
 Have constant interest to learn and mentor
Sensitive to realize the existence of problems first and

determined to drive towards solution
 Interested in sustainable development, lean operations and
effective utilisation of resources
Trainings & Certifications:
1. CNC programming and applications - 2003
2. Unigraphics-Nx - 2004
3. ISO 9001-Internal auditing- 2005
4. 7QC tools - 2005
5. Project implementation acceleration - 2011
6. Global supply chain concepts - 2018
Major inhouse trainings:
1. ISO 9001-2008
2. Medical quality management systems (MQMS)
3. Export compliance
4. Information security, Global data privacy protection
5. Mechanical lead courses (9 courses)
6. Project management (PMBOK Guide - 5th edition - 30+ courses)
7. Reliability - Introduction
8. Six sixma greeen belt
9. Xerography-Advance & Basic design guides to avoid paper jam (Media handling)
Papers published:
Published good practices papers on the following topics at HCL.
1. Transformation of test case to fixture design requirement
2. ROI estimation and financial viability analysis for cost reduction projects
Published a paper on following title in an international journal shortly named as “IJARMATE” as a
part of ME course.
Improving bicycle design by adopting advanced methods of force or torque conversion and
ergonomics principles (Volume III, Special Issue IX, March 2017; ISSN (ONLINE): 2454-9762; DOI
10.20256 / IJARMATE.2017.03S09030022)

EXPERIENCE PROFILE:
Organization: HCL Technologies Ltd, Sholinganallur, Chennai
Business unit: Engineering and R&D services
Role : Associate technical manager Period : Nov’ 2013 to Jan’ 2019
Role : Technical lead Period : Dec’ 2011 to Oct, 2013
Jobs performed:
Customer: Xerox Corporation,USA (Dec’2011 - Sep’2014)
Design & development of automated /semi-automated test fixtures for design verification and life
testing of subsystems (Toner dispenser module, By-pass tray module, Main drives module, Invert-Exit
module, Graphical user interface module, LED Print head module)
Planned and executed life testing of Left hand door module, High capacity feeder module and a
performance testing at the interface between MFP and stacker/stapler unit, assisted for Design of
experiment on By pass tray module.
Supported sub-system design teams to rectify the design problems (Redesigned spring loaded swing
gear mechanism for By-pass tray - LH door interface through proper tolerance stack up, Fine-tuned the
design parameters of gears for Toner dispenser module, Studied competitor’s by-pass tray assembly and
guided the design team to understand the components, function and helped in design calculations,
Reviewed the design of by-pass tray roller nip and suggested changes to avoid mis-feed and multi feed,
reviewed and suggested changes in drive system, invert-exit and LPH modules).
Assisted project mgmt. team in setting up / improving Mechanical Lab, competency mapping and
training need identification.
Customer: Manitowoc, USA (Oct’2014 - March 2015)
Concept generation and cost estimation for test rig for life testing of Ice box, Water control valve
and burst testing of ice bag.
Customer: Internal (Part of Mechanical practice team) (Oct’2014 - March 2015)
Guided the engineers to prepare a proposal on new “Card dispenser” for banking sector, provided
inputs on total number of cards used globally, its trend, manufacturers of card dispensers, their market
share, features of products available, Estimation of project cost, Estimation of sales volume, ROI from
manufacturer’s perspective, ROI from banks perspective, ROI from HCL perspective.
Customer: A bank from USA (April 2015 - June 2015)
Review and guidance of Should costing for a future ATM prototype design, Collation of System
requirement from customer requirement document and transformation into technical requirement,
Concept development for future ATM machine, Review of sub-system concepts.
Customer: Siemens healthineers, USA (July 2015 - Aug’2015)
Prepared a project proposal for cost reduction in Triple fan assembly of a medical diagnostic
equipment, Reviewed design and drawings of a test rig for diagnostic equipment subsystems and
provided review comments.
Customer: Internal (Aug’ 2015 - Sept’ 2015)
Concept generation for Proof of concept (POC) development to build Motion control area
capability.
Customer: Electrolux (Sept’2015 - Oct’2015)
Design and development of automated life test rig for a bellow tube of steam oven. The test rig was
designed to operate inside a climatic chamber with a maximum temperature of 140 degree Celsius for a
period of three hours in a test cycle. It was an automated test rig with PLC and HMI and 5/3 pneumatic
valve.
Customer: Siemens Healthineers, UK (Nov’2015 - Oct’2016)
Handled projects for cost reduction two Point of care equipments. Guided the team for sample
feeding device concept and detailed design.
Handled a team of design engineers, conducted tear down, brain storming, technical training
sessions, reviewed design ideas, concepts and Change proposals, feasibility reports, Project plans, etc.
Built a mechanical team, managed necessary resources including workstations,seats, CAD licenses,
Manpower requirement, Interviews, Project planning and Monthly review documentation, Project
management audit preparations, Corrective actions, Resource forecast, Time sheet, Billing, Customer
calls, etc.
Mechanical verification lab projects (Nov’2016 - July 2017)
Xerox corporation: Support for Design and development of test rig mechanical structure for 3 axis
robot for testing graphical user interfaces of electro mechanical products.
KLA-Tencor: Reviewed and suggested changes in test fixture part drawings
Electrolux: Supported to revamp old test rig from PLC based automation to LabVIEW based
automation.
SKF-Germany: Supported pre-sales team to prepare a response to an RFP for a legacy conversion
project. Provided a combination of data scenarios possible at customer end and approach towards
execution of the project.
Cisco: Studied test requirement from customer and suggested changes in design of test setup and helped
Mechanical verification lab to build a low cost test up.
Supply chain support projects (Aug’2017-July 2018)
Customer: Abbott, USA
Manufacturing capability development, Handling RFQ from customer, DFMA, Design and drawing
modification suggestions and arranging quotes from suppliers, Sourcing, Price negotiation, Estimate
preparation for customer.
Procurement of parts, Inhouse inspection and assembly of parts
Packing case development, packing & delivery related documentation management.
Customer: CSC Corporation
Understood product varieties (AEDs) of CSC, studied competitor products, features, sales potential
of AEDs, problems reported and identified potential cost reduction areas, Prepared a list of functional,
performance, safety, reliability requirements as per international standards, prepared mechanical
requirements specification, studied feasibility to achieve the proposed enclosure mass, comparison of
different materials for enclosure design based on different parameters like mass, price, mouldability,
EMI/EMC reduction, Thermal conductivity, etc.
Customer: ABB, Germany
Cost estimation for testing of Isolation flange of Laser gas analyser.
Test plan preparation, interacted with test labs to fine tune & finalise test method
Sourcing and procurement of prototype parts from different suppliers, budget estimate preparation,
project status preparation.
Other projects: Oxicool - Project cost estimation for performance testing of air distribution module of
HVAC system of a truck, Xylem - Cost estimation for prototype development of a modified booster
pump, Microsoft - Understanding and approach document on manufacturing feasibility for case of light
weight laptop, Abiomed - Reviewed fixture drawings and suggested design and drawing changes, ITT-
Estimation for development and testing of IE4 induction motor.
Customer: Caterpillar - Global (Aug’ 2018- Jan’2019)
RFP scope study, Preparation of project proposal, Feasibility report, Project cost estimation, ROI
analysis, Proactive proposal development by studying the market trends, Competitors, Market share,
opportunities, New regulations, etc. for Caterpillar delivery unit. (Margin improvement project,
Manpower augmentation project, Operation and service manual project, New opportunities with Marine
engines, gas engines, reverse engineering of heavy truck radiator components, etc.)

Organization : Rieter India pvt ltd, - A leading textile machinery manufacturer – Indian plant located
nearby Pune, Maharashtra to cater the need of the Asian market.
Role : Asst. Manager – R&D Period : April 2011 to Nov’, 2011
Role : Senior Engineer- R & D, Period : Oct’ 2009 to March 2011
Role : Engineer- R & D, Period : Jan’ 2007 to Sept’ 2009
Jobs performed : Worked in blow room (B26-waste opener) and ring spinning machine (G32) projects
Project 1: Waste opener machine
 Conversion of CAD data from old sheet metal bending norms to new, uploading in SAP PLM,
Material master creation
 Design of sheet metal parts as per machine skeleton drawing
 Updation of machined part CAD models and drawings
 In-house development of parts and machine assembly
 Functional testing of first prototype and refinement of design specifications
Project 2: Old version Ring spinning machine – Sustenance
 Studied the customer complaints and visited spinning mills to study the problems
  Studied the old designs and re-engineered the tangential belt pulley to avoid breakage
(Changed the material from Bakelite to ABS, modified the design to offset parting line to
central parting line)
 Studied the old design of twist wheel bearing assembly and identified usage of wrong type of
bearing (Full complement) and redesigned it with fixed bearing and correct fit. Also planned
and implemented interim solution to avoid bearing removal at customer site.
 Studied the old design of draft gearing bearing assembly - Identified thrust force induced by
helical gears as the cause for removal of DGB bearings from gear and redesigned with angular
contact ball bearings with back to back arrangement.
 Followed up till implementation of new solutions and ensured customer satisfaction.
Project 3: Ring spinning machine – New suction system
 Suggested a suction system for the new ring spinning machine in which the axis of suction
system aligns in a plane with suction duct to avoid reduction in suction pressure due to
direction changes.
 Initiated, designed, developed the new suction system tested in house and at customer site as a
performance measurement.
Project 4: Ring spinning machine – Relocation of mfg location
 Designed cast iron castings for new ring spinning machine
 Verified the UG models and drawings made by engineers for compliance with standards,
DFMA, GD&T, maintenance of material master & introduction document.
 Visited and evaluated foundries and suggested suitable suppliers for the requirement of castings
 Visited suppliers and supported sourcing team technically for developing Al extrusion profiles.
Project 5: Ring spinning machine – Cost down
 Performed as a leader of local design team for Cost Down (Value Engineering and Localization)
project – With a cost reduction target of 200 INR per spindle for the machine which was with
1440 spindles – At the end of my tenure, there were solutions in design and development stage
for about 40 INR out of opportunities identified for a value of 110 INR.
Small projects:
 Conversion of old sheet metal parts of Tube loader assembly of ring spinning machine (BT702)
to new bending norms as per Beyeler m/c standards.
 Design of a torque wrench for roller assembly
 Provided an innovative solution for apron tensioner assembly tool for easy installation
replacing the old tool used for more than 40 years, designed and developed the same.
 New concept design and POC trial for spring loaded back roller clearer roller system
 Lead raw material standardisation project for Indian manufacturing plant.
 Lead and completed a task of identification of equivalent and alternate lubricants available in
India for textile machineries.
 Standardised bearing suppliers to avoid mix and cost reduction.
Routine works:
 Handled new customer order specification development through selection of gears, spacers and
main drive motor selection based on power requirement calculation for various operating
conditions.
  Performed as SPOC between operations teams and design teams across globe for ECRs/ECNs
Handled ECRs. Handled about 230 ECRs and closed 200 of them in 1.5 years span.
 Handled quality deviations from inhouse manufactured, bought out parts and provided
disposition for the whole ring spinning machine (Signing authority for the deviations)- Whose
total worth of components was about 20 lakhs on average per month.
 Reviewed and approved first samples of various plastic moulded and Al die cast parts.
 Internal audit on departments for compliance with Integrated management system (IMS)
Software used : 3D modeling software - Unigraphics –NX1 to NX6 and Material data base -WIAM
Organisation: Lakshmi Automatic Loom works Ltd., Coimbatore a well known ISO 9001 : 2000
Certified organization of Lakshmi Mills Group for mfg. High profile circular knitting machinery
& spares, and also functions as a 100% EOU for mfg. VDI Tool holders & Tool holder parts.
Role : Asst. Engineer - Tool planning Period : Sep. 2004 to Jan 2007.
Jobs performed:
 Tool planning for 60 selected parts (KANBAN parts) of Job shop production, Procurement of
tools worth 50 Lakhs as a special project to preload CNC machines with tools for setup time
reduction.
 Tool crib management
 Tooling inventory management and optimising tool procurement cost by fixing reorder level
 Identifying potential improvement opportunities, planning short term / long term quality
objectives/ preparation of action plan, execution and continual improvement
 Internal audit on Production, PPC, Production engg, Assembly & Stores departments for
compliance with ISO 9001 : 2001
Organization: G.T.N. Exports ltd., Coimbatore. - A DNV certified ISO-9001 company and API
registered firm mfg. industrial gate valves and valve assemblies.
Role : Trainee Engineer - M/C shop (Programmer &Operator – HMC - Fanuc O-M)
Period : August 2003 – March 2004
Organization: Sri Ranganathar Industries Pvt. Ltd., Coimbatore -25. - A TUV certified ISO-9001
company and API registered firm mfg. industrial valves and valve castings.
Role : Supervisor - M/C shop (Conventional lathe and Milling machines)
Period : July 2002 - May 2003
Organisation: Lakshmi Synthetic Machinery Mfrs. Ltd., Coimbatore (Dist) - A well renowned
company of Lakshmi group, which was mfg. synthetic yarn draw texturizing M/C s.
Role : Graduate Apprenticeship Trainee (Production - Machining & Fabrication shops)
Period : Nov’2000 – Oct’ 2001