Description

A result-oriented Project Manager with 12+ years of experience within Global Tier-1 Automotive manufacturing, specialising in the operational execution and sustaining engineering of complex safety-critical thermo-mechanical products. Expert in leading complex assembly projects from concept to final sign-off, with deep mastery of APQP, PPAP, and IATF 16949 standards and cross-functional teams to deliver end-to-end solutions within highly regulated frameworks. Proven track record in managing integrated project plans, including budget, resource levelling, and risk mitigation. Highly qualified with an MSc in Project Management, offering deep expertise in Lean manufacturing, FMEA, and BOM management to ensure product safety, quality, and cost targets are met. Proven track record of managing high-value programs for OEM clients, ensuring delivery within budget and strict timing plans. Skilled in DFMEA, 8D Root Cause Analysis, and DFM optimisation, with a passion for driving sustainable automotive innovation.

Languages

English
Native or bilingual

Workplace preferences

Can work on-site

London (up to 50km)

MAHLE Engine Components,
PROJECT MANAGER, DESIGN & DEVELOPMENT (Technical Project Management)
AUTOMOBILE
September 2014 - February 2025 (10 years and 5 months)
India
Role Scope:
Accountable for the execution effectiveness of operations and sustaining projects for a range of high precision thermo-mechanical, highly safety-critical components. Acted as the technical project authority for the design and manufacture of powertrain hardware, ensuring all projects were compliant, cost-effective, and delivered to strict OEM timelines. Translated customer needs into robust technical specifications, performed feasibility assessments, developed technical proposals, and partnered with cross-functional teams to ensure successful project delivery.

 End-to-End Project Ownership: Led the planning, manufacturing, and commissioning of high-load and safety critical mechanical systems, ensuring 100% on-time delivery against agreed KPIs and timing plans.
 Project Execution: Led cross-functional teams (Design, Quality, Production) to implement end-to-end deliverables for current product ranges, ensuring zero disruption to supply.
 Integrated Planning: Headed the development of project charters, resource plans, and risk registers, keeping high-value projects on track and within budget.
 Manufacturing Support: Supported the ongoing manufacture of high-quality products by updating Bill of Materials (BOM) and assembly procedures to reflect continuous improvement initiatives.
 Issue Management: Managed tactical details, including action items and decision logs, facilitating rapid resolution of manufacturing blockers.
 Quality & Safety: Ensured all sustaining solutions met stringent safety and quality targets, utilising Lean philosophies to reduce waste and improve delivery.
 Strategic Project Delivery: Supported the delivery of key transformation initiatives to modernise engine component systems, aligning technical roadmaps with broader organisational strategy.
 Matrix Collaboration: Worked within a complex matrix structure, coordinating resources across R&D, manufacturing, and executive leadership to ensure project objectives were met.
Technical project management Project Planning Product Development Stakeholder Management Risk Management
NOVA-GLOBAL Technosoft,
PROJECT ENGINEER – Design & FEA Simulation (CAE)
May 2011 - May 2013 (2 years)
Bengaluru, Karnataka, India
Role Scope: Conducted advanced FEA simulations to validate the performance of mechanical components in early stage R&D projects. Performed structural analysis, thermal simulations, and material integrity studies to support the
development of components for the automotive sector.

Key Responsibilities & Achievements:
 Design Validation: Conducted advanced structural assessments and stress analysis to support early-stage automotive R&D.
 Robustness Studies: Performed material integrity studies to meet customer performance expectations and
durability benchmarks. Core Technologies: CAD – CATIA, Pro/E | FEA – Ansys, Abaqus, HyperWorks | CAM – DfX, DFMEA, GD&T, Standards

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MSc Project Management
York St John University
2026
London, The UK
MEng Design & Manufacturing
St Peter's University
2015
Chennai, India

Rajkumar Mani

PROJECT MANAGER, PRODUCT DESIGN & MANUFACTURING

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