Rasu’s expertise extends into the mining industry, where he has focused on developing driveline components for underground vehicles.
Sakthivel Rasu
Automotive and mining industries are undergoing a transformative period, driven by advancements in product design and development which emphasize innovation, efficiency, and sustainability. As the industryadvances to the future, it is believed that the integration of digital tools and data analytics will continue to revolutionize product design, enabling even greater efficiencies and quality improvements. Sustainability will play a crucial role in shaping future product development. Innovations in materials and manufacturing processes will be essential to meet environmental standards while maintaining performance.
ADVERTISEMENT
Belonging to this domain, Sakthivel Rasu, a seasoned professional, has led numerous projects that exemplify these trends, significantly impacting product performance and organizational success. Beyond his technical contributions, Rasu has deeply committed to mentoring the next generation of engineers. He said, “I have taken pride in mentoring younger engineers, sharing my knowledge of advanced engineering techniques, and helping them develop the skills needed to succeed.”
He has contributed to his organisation’s success in the automotive landscape through various ways. The end-to-end design and development of the B6.7L valve train components, demanded meticulous oversight through various stages-from initial concept to full production. Theyconsist of essential elements such as non-brake rocker levers, hydraulic lash adjusters, solenoid valves, and cam phasers. The successful management of technical content reviews (TCR) along with active collaboration with suppliers assisted the innovative design enhancements which optimized product durability while adhering to strict performance and cost criteria.GDI fuel pumps and fuel injectorsare other vital components, significantly enhancing vehicle performance and reliability. With advanced prototyping techniques, such as 3D printing, the product testing and validation processes were accelerated. This capability allowed his organisation to bring prototypes to market more rapidly and with fewer iterations, ultimately leading to shorter production timelines.
Rasu’s expertise extends into the mining industry, where he has focused on developing driveline components for underground vehicles. Applying Failure Mode and Effects Analysis (DFMEA), Design for Manufacturing (DFM), and Design for Assembly (DFA) principles ensured that products were not only high-performing but also cost-effective to manufacture. Another significant project involved redesigning shafts and differential spiders, which required balancing robust durability with tight production schedules.
Addressing supplier quality issues which arose during the development phase was challenging buttheclose collaboration with purchasing and quality teams, these concerns were identified and mitigated. It resulted in a remarkable 2% cost reduction-approximately $1.5 million-on driveline components, and it was largely due to optimizing designs to minimize scrap rates and enhance material usage, demonstrating how engineering and cost-saving measures can coexist.Collaboration has been a cornerstone of a successful approach to product development. Engaging with both internal and external stakeholders has proven essential in refining processes such as Design Validation Plans & Reports (DVP&R) and Advanced Product Quality Planning (APQP).
The root cause analysis techniques, like Fishbone Diagrams, can be used to systematically address failures in underground mining products. It can lead to corrective actions that improve product quality and minimize downtime forcustomers. Critical failure points should be focused upon for enhancing the current product line and implementing preventive measures to reduce future failure rates significantly.
The quantifiable impact of these efforts is evident in several key metrics. In addition to achieving a $1.5 million cost savings through optimized driveline component designs, approximately $6 million was generated in aftermarket revenue by standardizing products and improving branding strategies. This involved detailed cost studies and product validations to ensure that high standards were maintained while achieving significant revenue growth.Introduction of advanced manufacturing techniques allowed the streamlining of production processes, thereby reducing waste and improving efficiency.
In conclusion, the advancements in product design and development within the mining and automotive industries highlight a broader commitment to quality, efficiency, and collaboration. As these challenges are navigated, the industry is optimistic about the potential for continued innovation and growth.
Subscribe today by clicking the link and stay updated with the latest news!" Click here!
