K G Madhavan
@kgmadhavan
I lead gasoline calibration and BS6.2 homologation for high-performance vehicles.
IndiaWhat I'm looking for
I lead gasoline vehicle calibration at Mahindra & Mahindra, delivering BS6.2-compliant calibration for Thar and Thar Roxx programs. My work improves performance, emissions compliance, and homologation timelines across engine dyno, on-road, and high-altitude validation.
Previously at Garrett Motion, I led VNT and wastegate turbocharger product development, qualification, testing, FMEA, and failure investigations for Mahindra gasoline and CNG applications. I also developed diesel injectors and fuel injection pumps for BS6 programs at Delphi-TVS.
I've built MATLAB/Simulink tools, resolved technical bottlenecks, and aligned cross-functional teams around engineering precision, performance, and compliance. I bring more than 10 years of automotive R&D experience spanning calibration, powertrain integration, fuel systems, and product development.
Experience
Work history, roles, and key accomplishments
Lead Engineer - PTD
Dec 2022 - Present (3 years 9 months)
* Led Calibration activities for multiple Mahindra Thar models, including BS6.1, BS6.2 Ph 1, BS6.2 Ph 2, and BS6.2 Ph 3.
* Oversaw calibration for an upcoming Mahindra Thar project, resulting in significant timeline reductions for homologation.
* Successfully conducted 6+ quality gateways throughout the project lifecycle to ensure timely and high-quality deliverables.
* Implemented lead calibratio
o New Product Development for VNT Turbocharger & Waste Gate Turbocharger for Mahindra Application 1.2L Gasoline, 2.0L Gasoline & 1.5L CNG.
o Ensuring designs and systems meet the quality, cost and budget specifications.
o Checking suitability of the systems, mechanisms and functionality of the Turbocharger to suit future BS standards
o Generating ideas in areas of designing components and systems
o New Product Development of diesel injector for Hyundai Motor Corporation, Tata Motors Limited, JCB, Simpson & Co. , Escorts Limited & Sonalika Tractors for BS6 Standards.
o Ensuring designs and systems meet the quality, cost and budget specifications.
o Checking suitability of the systems, mechanisms and functionality of the injector to suit future BS standards
o Generating ideas in areas of des
o New Product Development of diesel injector for Volvo Eicher, Force Motors Ltd., Mahindra & Mahindra, Hyundai Motor Corporation, JCB , Tata Motors & Ashok Leyland for BS6 Standards.
o New Product Development of a new design pump with Engineering & Design department for Guangxi Yuchai Machinery Group Co., Ltd., Volvo Eicher, Force Motors Ltd., Mahindra & Mahindra, Wuxi Wolffu, Yuchai & YTO & Ashok
o New Product Development of a Fuel Injection Pump for Ashok Leyland, Mahindra & Mahindra, Force Motors Limited & Volvo Eicher for BS6 Standards.
o Preparation of PPAP Certification dossier
o Supporting of installation and commissioning of new plant and machinery, component machining trials and establishing regular production. Have established special purpose machines such as Electro Deburring Mac
o Preparation of APQP timing Plan (Macro & Micro) and engaging in APQP activities for new projects.
o Preparation of manufacturing documents like Operations layout, Tooling layout, Product Control plan, PFMEA and Process Control plan for the product/manufacturing cell assigned and organize for new tools and gauges required.
o BOM creation & SAP system handling for new products.
o Trouble shooting
o Performed diagnostic and troubleshooting procedures to find and identify root causes of mechanical issues.
o Replaced damaged, missing or defective parts with new and refurbished components.
o Motor Mechanic for 2 Wheelers
o Specialized in Engine troubleshooting & Assembly, Carburetor tuning
o Reduced Shaft deflection in AHT by using Vulcanized rubber seals increasing Shaft life by 10%.
o Improved overall efficiency by 4% by introduction of Hybrid motor coupled with Engine propulsion system.
o Improved overall efficiency by 7% by introduction of water treatment system in the cooling system.
Education
Degrees, certifications, and relevant coursework
1% Club
Personal Finance Mastery, Personal Finance
United Latino Students Association
Power BI Workshop
Issued Jul 2025
ISBM University
Master of Business Administration - MBA, Project Management
2019 - 2021
NPTEL
Electric Vehicles and Renewable Energy
Issued Nov 2021
Anna University Chennai
Bachelor of Engineering (B.E.), Mechanical Engineering
2012 - 2016
o First Class in B.E. Mechanical Engineering
o Collection of clothes and utensils for old age homes
o Blood donation at the Lions Club donor bank
o Afforestation drive at Vel Tech Campus and Avadi in 2012.
o Eye testing for the underprivileged in Kanniamman nagar, Avadi in 2013
o Event Manager and Assistant Web Designer at National Level Conference INOMAS’13 at Vel Tech, Avadi
o Blood Pressure
SBOA School and Junior College
High School, Mathematics and Computer Science
2000 - 2012
Availability
Location
IndiaAuthorized to work in
Salary expectations
Social media
Job categories
Skills
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