Gaurav Pratap Singh

Results-driven NPD Engineer & Project Leader with hands-on experience in aerospace and defense investment casting at Aerolloy Technologies (a PTC Industries subsidiary). Proven track record of leading 4–6 complex NPD projects end-to-end — achieving 75% on-time delivery and reducing casting rejection rates by 47% (from ~15% to ~8%) — for global clients including Dassault Aviation, Siemens Energy, Sulzer, and Meril Healthcare. Skilled in APQP, PPAP, FMEA, QAP, Control Plans, Root Cause Analysis, Six Sigma, and AS9100 compliance.

Adept at driving cross-functional teams across design, procurement, quality, and manufacturing to deliver defect-reduced outcomes in high-stakes aerospace environments.

NPD Engineer & Project Leader - Aerolloy Technologies Limited (A subsidiary of PTC Industries Limited) - Lucknow, Uttar Pradesh

(2024-09)

• Led 4–6 end-to-end NPD projects for aerospace clients including Dassault Aviation, Siemens Energy, Sulzer, and Advance Valve — delivering 3 out of 4 projects on time (75% on-time delivery rate) and releasing 3 complex aero-engine components into full production with zero documentation gaps.
• Reduced casting rejection rate from ~15% to ~8% — a 47% improvement — through structured application of Six Sigma techniques and 7 QC tools across wax injection, shell dipping, firing, and alloy pouring process stages.
• Raised and resolved 10–20 NCRs for process deviations, coordinating with quality and operations teams to drive root cause identification and CAPA execution — preventing recurrence across investment casting processes.
• Coordinated a cross-functional team of 4–6 members across design, procurement, quality, and manufacturing — tracking milestones across 4–6 concurrent NPD projects and maintaining project delivery discipline in a high-specification aerospace environment.
• Developed and maintained 100% AS9100-compliant NPD and quality documentation — including QAP, PFD, Control Plans, SOPs, and Work Instructions — across all NPD projects with zero audit findings.
• Standardised process parameters across all 4 investment casting stages — wax injection, shell dipping, firing, and alloy pouring — reducing process variation and supporting first-time-right casting outcomes.
• Established process documentation (SOPs, technique sheets, WIs) aligned with international standards and client compliance needs, supporting continuous improvement initiatives that enhanced manufacturing efficiency and process consistency.
• Liaised with customer technical teams to clarify engineering specifications, drawing requirements, and quality standards — ensuring full alignment between client expectations and internal production capabilities before process freezing.
• Maintained structured document control system for all engineering, NPD, and quality records — ensuring version control, timely reviews, and audit readiness in line with AS9100 and international manufacturing standards.
• Supported continuous improvement initiatives by analysing process documentation gaps, implementing corrective SOPs post-NCR closure, and updating control plans to prevent recurrence of casting defects.
• Reduced casting rejection rate by 47% (from ~15% to ~8%) through Six Sigma and Root Cause Analysis — directly improving production yield and reducing rework costs across multiple component families.
• Successfully developed 3 complex aero-engine components (Advance Valve, Dassault Aviation, Sulzer) with complete NPD documentation — released for series production on schedule with zero quality escapes.
• Resolved 10–20 NCRs within project timelines, maintaining compliance with AS9100 and customer-specific quality requirements across all active NPD projects.

Bachelor of Technology - Mechanical Engineering - R.R. Institute of Modern Technology, Lucknow (Dr. A.P.J.

Abdul Kalam Technical

University) (2024)

Intermediate (CBSE) - Govt.

Boys Senior Secondary

School, Shabad Daulatpur, New Delhi (2020)

High School (UP Board) - SB Inter College, Sadi Khurd, Kushinagar (2018)