Vijay Raj

Experience

1. Process Engineer

   Ather Energy

   Jul 2022 — Present · Hosur, IN

   As a Process Engineer at Ather Energy, I am actively involved in optimizing production processes, implementing lean manufacturing practices, and leading critical improvement projects in the vehicle assembly line. My responsibilities span cross-functional collaboration, line setup, documentation, and project execution to support existing operations and readiness for future models.Key Responsibilities & Achievements:Midframe Conveyor Project: Led the execution and commissioning of the Midframe Conveyor System from DAP to final handover, improving line flow and material handling efficiency.Battery Slider Implementation: Successfully implemented a battery slider mechanism in the vehicle assembly line, improving ergonomics and reducing cycle time in the battery installation process.Model Readiness & Line Setup: Ensured sub-assembly and line-side readiness for upcoming vehicle variants, including APEX, with internal fixture design, manufacturing, and documentation readiness.Rejection Cost Reduction (SPOC): Served as the Single Point of Contact (SPOC) for rejection cost reduction initiatives—brought down the scrap cost per vehicle from ₹135 to ₹8.2 through targeted analysis and process improvements.Process Documentation Owner: Developed Ather-standard templates and managed key documents including PFDs, PFMEA, Control Plans, and Work Instructions—ensuring audit readiness and shopfloor compliance.MOST & NVA Study: Conducted cycle time studies using the MOST method to identify and eliminate non-value-added activities in the vehicle line process.Scratch Reduction Project: Initiated and executed an internal project to reduce scratch-related rejections by developing protective covers for body panels without compromising assembly procedures.Six Sigma Black Belt: Achieved Six Sigma Black Belt Certification from TÜV SÜD, enhancing capabilities in data-driven problem solving, root cause analysis, and continuous improvement.

Education

• Global Institute and Technology

  Bachelor, Mechanical Engineering

• Vellore Institute of Engineering and Technology

  Master, Manufacturing