Jayamuthu Kailash Karthikeyan
Columbus,IN
Summary
Result-driven Senior Technical Specialist at Cummins Inc., leveraging expertise in MATLAB and project management to drive innovative fuel system solutions. Recognized for developing advanced test methodologies and securing patents, while fostering cross-functional collaboration to enhance product performance and reliability. Proven track record in analytical problem solving and continuous improvement initiatives.
Overview
11
11
years of professional experience
1
1
Certification
Work History
Senior Technical Specialist- Fuel System Performance
Cummins Inc
Columbus, IN
02.2024 - Current
- Developed advanced test methodologies and automated test stand operations using UNIX scripting, driving continuous improvements in test stand capability, scheduling efficiency, and maintenance reliability.
- Executed standardized performance testing for high‑ and low‑pressure fuel systems, applying production‑grade protocols to ensure manufacturing quality and product consistency.
- Analyzed, visualized, and interpreted complex test datasets using MATLAB, Excel/VBA, and Minitab, delivering actionable insights through statistical analysis and simulation‑based modeling.
- Built comprehensive 1D simulation models from empirical test data to accurately predict product behavior across operating scenarios, enabling design teams to optimize performance and assess application suitability. These models are developed based on actual test results thus capture the entire physics so the predicted results are close to reality.
- Developed custom simulation tools and implemented both invasive and non‑invasive measurement techniques to characterize fuel system performance with high fidelity.
- Partnered with product support teams to diagnose and resolve performance issues on released products, providing critical test and simulation findings to inform new product development decisions.
- Interpreted customer and regulatory requirements, authored detailed validation plans, and mentored engineers in fuel system testing methodologies and best practices.
- Led benchmarking initiatives to evaluate competitor technologies and develop new concepts aimed at improving fuel system efficiency.
- Submitted two patents: one approved and one currently under review.
Senior Product Engineer - Fuel pump Development
Cummins Inc
Columbus, IN
06.2022 - 02.2024
- Leading various product development projects on Low pressure pump for Cummins fuel systems.
- Concept and evaluation of technology for next generation of fuel-lubricated pumps.
- Ideation of different concepts solutions for various components via 3D modeling, bench prototyping and component-level analysis.
- Interacted with customers, identified needs, and brainstormed methods to translate the developed technology to meet customer specifications.
- Led cross functional discussions with a global team to design the technology for compatibility with assembly, manufacturing and fitness to market.
- Procured prototypes and designed test plans to validate the top level assembly for performance, reliability, sustainability and cost.
- Optimized DVP&R using iDFMEA to minimize consumer risk and ensure smooth product introduction at the customer end.
- Led product problem solving activities using 7 step process, with emphasis on FTA for identifying assignable cause and RCA to ensure continuous improvement.
Development and Research Engineer
Caterpillar Inc
Pontiac, IL
04.2021 - 06.2022
- Performing design improvements and implementing new designs on high-pressure fuel pumps used on CAT generators. Running computer simulations and validation tests on test beds available in the facility.
- Redesigned the pump plunger cooling flow path for ease of manufacturing, increasing performance, and improving the sealing surface on the joints. The design is verified using Dynasty which is a system simulation tool developed by Caterpillar and performed pump system bench tests at the lab.
- Worked on the design improvement of the displacement control system on a variable displacement type fuel pump to improve the first test pass rate. Created Dynasty model and conducted test validation on the changes at the CAT facility.
- Changed the design of control blocks used on a pump, so that they can be reused at the remanufacturing facility thus reducing scraping of parts. This is projected to save a lot of money for the company. Used Creo 4.0 to do the design changes.
- Working on a cavitation issue on a solenoid-controlled control valve on one of the high-pressure pumps. Using Ansys Fluent to run flow simulation. developing various test procedures to replicate the operating conditions on the field in order to validate the pump.
- Conducting validation of products manufactured at the facility at a regular interval to maintain quality reports. Supporting the production line if they run into problems while machining the parts like tolerance issues or material damage issues.
- Conducting a detailed study on the pumps returned from the field for improving the existing design, so that increasing the reliability of the product and reducing the warranty claim.
Manufacturing Process Associate
Honda Of America
Marysville, Ohio
08.2020 - 04.2021
- Supervising various manufacturing functions while coordinating with the assembly team of Honda on various models, such as Acura, Civic, and Accord models.
- Performing maintenance of hydraulic and pneumatic lift assist machinery used in the shop floor at the production line.
- Improved everyday production target by 20% by conducting Dynamic quality checks, performing continuous improvement in the process by predicting assembly problems, and suggesting solutions.
Mechanical Design Engineer Intern
NCR Corporation
Atlanta, GA
05.2019 - 08.2019
- Held full accountability for demonstrating, modeling, and designing 3D printed parts and assemblies.
- Conducted structural failure analysis of the designed parts and assemblies using Ansys Workbench.
- Utilized hands-on knowledge of PTC Creo to create parts for a new bar code scanning machine in NCR.
- Used LabView Data acquisition tool to get reading and to control the various parameters of the testbed.
- Prepared part and assembly drawings based on engineering principles and data for design review.
- Facilitated engineers at NCR in gathering scanner modules and executing endurance tests on the product.
- Implemented plans to ensure proper airflow over the motherboard to carry away the heat effectively by adding baffle plates, used ANSYS Fluent simulations to visualize the flow of air for that arrangement.
Senior Service Engineer
L&T Shipbuilding Pvt LTD
, India
07.2015 - 07.2018
- Headed various complex technical projects, such as HVAC, hydraulics systems, and marine diesel engines overhauling in a timely manner and followed proper safety regulations and engineering procedures.
- Specialized to work on marine diesel engines and hydraulic systems.
- Conducted dimensional checks on small intermediate propeller shafts of ships.
- Rendered a keen eye for details to administer machining equipment like LATHE, milling machine, surface grinder and fabricated many parts for different types of machinery.
- Trained on GD&T.
- Developed strategic plans to focus on proper construction and troubleshoot of equipment and to reduce the capital budget involved in the projects.
- Improved performance of machinery on ships, such as hydraulic/steering system, diesel generators, pump, valves, gearbox, powertrain engineering, propeller shaft, marine diesel engines, and HVAC plants.
- Designed and established an oil pump testing bed following IS 5167 and BS 1042 engineering standards. Used PTC Creo to design and used Ansys Workbench to decide the dimensions of the pipe and the orifice plate for the oil pump testbed. This led to cost reduction of overhauling oil pumps by 40% each project.
- Established gas cylinder testbed based on non-water jacket hydro-testing method, which cutoff the cost involved in testing the cylinders outside the plant.
- Handled complete repairing and maintenance of various HVAC chiller plants, such as overhauling compressor and pressure testing of condenser, pipelines, and evaporator.
- Executed revamping, troubleshooting, onsite commissioning, and testing of marine diesel engine parts by performing fuel injection/valve timing, fuel pump calibration, vibration analysis of mounts, and tuned droop setting controls of governors to achieve load sharing of engines.
- Successfully resolved issues on the hydraulic system in cranes, winches, and anchors, by reading hydraulic circuit drawings and technical specifications.
- Conducted complete repair of hydraulic pumps, motors, and cylinders.
- Installed and pressure tested piping layout of hydraulic systems, HVAC systems.
- Performed cooling and heating load calculations for small spaces using the E20 method.
- Eliminated vibration and heating of bearings, mounts, couplings by implementing proper alignment between different parts of machinery and increasing the lifetime of the equipment.
Education
Master of Science - Engineering Management
Trine University
Angola, Indiana, IN12-2025
Master of Science - Mechanical Engineering
University of South Florida
Tampa, Florida05.2020
BE - Mechanical Engineering
Coimbatore Institute of Technology
India05.2015
Skills
- CAD software proficiency
- MATLAB application
- Project management
- Data analysis
- Product testing
- Cross-functional collaboration
- Test automation
- Simulation tools expertise
- Python programming
- Office productivity suite
- Design engineering
- Thermal and CFD analysis
- GD&T knowledge
- Diesel engine technology
- Analytical problem solving
- Product research and development
- Project planning
- Leadership and team dynamics
- FEA techniques
Certification
Fundamentals of Engineering (FE), https://account.ncees.org/rn/2111919-1309071-f8312f9
Timeline
Senior Technical Specialist- Fuel System Performance
Cummins Inc
02.2024 - Current
Senior Product Engineer - Fuel pump Development
Cummins Inc
06.2022 - 02.2024
Development and Research Engineer
Caterpillar Inc
04.2021 - 06.2022
Manufacturing Process Associate
Honda Of America
08.2020 - 04.2021
Mechanical Design Engineer Intern
NCR Corporation
05.2019 - 08.2019
Senior Service Engineer
L&T Shipbuilding Pvt LTD
07.2015 - 07.2018
Master of Science - Engineering Management
Trine University
Master of Science - Mechanical Engineering
University of South Florida
BE - Mechanical Engineering
Coimbatore Institute of Technology