Manikandan Rajasekar
Glasgow,United Kingdom
Summary
Experienced manufacturing professional with over 12 years of expertise in high-pressure die casting and machine shop operations, specializing in the production of precision components, melting processes, and machining. Proven track record in optimizing production capacity, reducing rejection rates, and delivering high-quality parts on time through strategic resource management, MRP-based planning, and lean practices such as Kanban and TPM. Skilled in supervising engineering teams, maintaining inventory control, and ensuring compliance with IATF 16949 and IMS standards. Proficient in SAP, MIS reporting, and vendor coordination, with a strong focus on operational efficiency, quality improvement, and customer satisfaction.
Overview
11
11
years of professional experience
6
6
years of post-secondary education
1
1
Certification
Work history
PDC – Production and New Product Process Development
Carlton Die Casting
Paisley, UK
04.2024 - 06.2025
- Led production planning and control to align capacity, materials, and schedules, consistently achieving on-time delivery targets.
- Optimized inventory levels and material flow to ensure uninterrupted production operations.
- Implemented process improvements and best practices across production and quality functions, boosting operational efficiency.
- Spearheaded new component development from die casting tool concept through mass production, including PQ2 analysis and parameter finalization.
- Managed die casting automation, robot programming, and tool maintenance, enhancing productivity and reducing downtime.
- Conducted FMEA, PPAP documentation, and process validation for new dies to ensure high-quality, repeatable production.
- Led root cause analysis and applied Poka-Yoke techniques to resolve production issues and reduce internal/external rejections.
- Coordinated cross-functional teams for troubleshooting, customer complaint resolution, and CAPA implementation.
- Monitored bottlenecks and executed line balancing and tooling improvements using VSM and ECRS methods to cut lead times.
- Hands-on experience with casting and machining of Aluminium, Titanium, Nickel, Zinc, and Lead alloys, ensuring quality aerospace component manufacturing.
Casting Production Senior Engineer
Minda Industries Limited
Hosur, India
07.2017 - 11.2023
- Led the development and production support for ZF and Volvo high-pressure die casting (HPDC) projects, ensuring successful tool launch and performance.
- Proficient in operating high-tonnage HPDC machines, CNCs, continuous melting systems, and post-casting processes such as fettling, buffing, and shot blasting.
- Directed cross-functional efforts in design, release, and validation of casting parts across battery programs, ensuring adherence to cost, quality, and functionality targets.
- Implemented DFMEA, Poka Yoke, and DFM/A strategies to integrate quality into the manufacturing process and reduce defect rates.
- Managed supplier engagement from Statement of Requirements to prototype and production tooling through GSP and sourcing processes.
- Delivered process improvement and cost savings through KPI monitoring (OEE, scrap, rework) and Kaizen-driven shop floor initiatives.
- Spearheaded the analysis and resolution of manufacturing issues using Global 8D methodology, ensuring root cause identification and corrective action.
- Oversaw tool design, gating calculations, shot simulation (PQ²), and die layout optimization to ensure casting feasibility and repeatability.
- Ensured compliance with IATF 16949 standards, maintained work/process documentation, and led audits in production and tooling operations.
- Demonstrated strong leadership and team development skills by building cross-functional teams and leading continuous improvement projects like TPS and Quality Circles.
Trainee engineer / Engineer
CASTWEL Auto parts PVT LTD
Chennai, India
05.2014 - 07.2017
- Operated and maintained high-pressure die casting machines (e.g., Buhler DCMs), including tool setup and CNC operations, ensuring smooth and consistent production.
- Recovered and programmed ABB robots from emergency stops and performed basic automation tasks to support seamless manufacturing flow.
- Led changeover activities using SMED/QCO methodologies, reducing downtime and improving machine utilization through structured changeover planning and reporting.
- Conducted TPM activities such as lubrication, cleaning, and early fault detection to minimize unplanned breakdowns and maximize productivity.
- Coordinated closely with the tool room and process engineering team to ensure die availability, pre-heat preparation, and process parameter optimization for new dies.
- Implemented 5S principles and in-house process audits to maintain organized, efficient, and safe work environments across the production floor.
Education
MBA - Operation Management
Roever Management Institute
India 05.2018 - 04.2020
B.E - Mechanical Engineering
Roever college of Engineering & Technology
India 06.2010 - 04.2014
Skills
- Pro E and AutoCAD
- Microsoft Office Suite
- SAP software
- Change management
- Lean manufacturing
- Operations management
- Data analysis and collection
- KPI development
- Problem-solving techniques
- Process improvement strategies
- Manufacturing process design
- Cost control measures
- Innovation
Certification
- Auto CAD, 03/2012
- Pro E, 07/2013
- IATF 16949 Internal Auditor, 09/2021
Accomplishments
1. Won Winner award in CII-National level Lean POKA YOKA Competition (2021).
2. Won Winner award in CII-National level KAIZEN Competition (2021).
3.Won Platinum Award in QCFI International Level Convention (2019)
4.Won Gold Award in QCFI Hour/Chennai/Varanasi chapter in QCC Competition (2018,2019,2020 & 2021)
5. Won Rhodium award in ABK- AOLTS QC Competition (2020&2021).
6. Won Per excellence award in QCFI International Level convention (2021).
7. Won Per Excellence Award at the QCFI National 5S Convention (2022).
8. Won a Gold award in the ACMA QC competition (2020&2021).
9. Won 2nd place in the QCI quality competition.
10. Won an ALUCAST best casting and best project of the year (2022).
11. Won the GDC TECH best casting of the year and best project of the year (2021&2022).
12. Won Per Excellence award at the QCFI National QC competition (2023).
Languages
English
Advanced
Hindi
Advanced
Tamil
Native
Timeline
PDC – Production and New Product Process Development
Carlton Die Casting
04.2024 - 06.2025
MBA - Operation Management
Roever Management Institute
05.2018 - 04.2020
Casting Production Senior Engineer
Minda Industries Limited
07.2017 - 11.2023
Trainee engineer / Engineer
CASTWEL Auto parts PVT LTD
05.2014 - 07.2017
B.E - Mechanical Engineering
Roever college of Engineering & Technology
06.2010 - 04.2014
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