Sathiaraj Rajendran

Welcome to My Professional Portfolio

Sathiaraj Rajendran | Project Manager | Digital Twin Specialist | BIM & Factory Layout Engineering Expert

With 11+ years of experience in Digital Twin Engineering, BIM Coordination, Factory Layout Design, Plant Simulation, and Manufacturing Optimization, I have built a strong record of delivering highly accurate, cost-efficient, and scalable engineering solutions across globally recognized organizations such as CY4 Digital Twin Product & Solutions, Mercedes-Benz R&D (MBRDI), Ford Motors, and Caterpillar India.

I bring proven expertise in 3D modeling, clash detection, process optimization, reverse engineering, and cross-functional project coordination. My work focuses on enhancing manufacturing efficiency, reducing clashes and rework, improving space utilization, and enabling digital factory transformation through BIM 360/ACC, Navisworks, Revit, AutoCAD, and Plant Simulation tools. I am recognized for my structured execution, stakeholder communication, analytical thinking, and ability to lead high-performing engineering teams of 60+ members.

My Expertise

Digital Twin Execution, BIM Coordination, Factory Layout Engineering, Plant Simulation, Autodesk Revit, Navisworks Manage, AutoCAD/MEP, Point Cloud to BIM, Reverse Engineering, Clash Detection, 3D Modeling, Cloud Collaboration (BIM 360/ACC), Project Lifecycle Management, Resource Planning, Stakeholder Alignment, Risk Management, Process Optimization, Factory CAD, Team Leadership & Training.

Professional Journey

I began my career as an Assistant Engineer at Caterpillar India and steadily advanced through roles in factory layout, ergonomics, simulation, and design validation. My journey across Ford Motors, Mercedes-Benz R&D (MBRDI), and now CY4 Digital Twin has shaped me into a versatile engineering leader proficient in delivering digital factory models, optimizing layouts, resolving complex interferences, and driving Industry 4.0 initiatives. Over the years, I have successfully reduced layout clashes by 20%, improved space utilization by 15%, reclaimed 27,000 sq ft of factory space, standardized model workflows, and led multi-disciplinary teams towards precise and timely project execution.

Vision & Dedication

I thrive in engineering environments where digital intelligence, manufacturing design, and operational excellence come together. My goal is to continue contributing as a Project Manager, Senior BIM Lead, or Digital Twin Engineering Manager—driving factory modernization, improving workflow efficiency, and enabling scalable digital transformation across industries.

With deep technical expertise, strong leadership abilities, and a commitment to quality, I am confident in delivering engineering outcomes that support organizational growth, innovation, and long-term success.

Sathiaraj Rajendran

Nick Name: Sathia

Email: sathiaraj.rajendran@gmail.com

Mobile: +91 8939381661, 8870613544

Location: Chennai, India

My Skills

Having worked within the industry for over 11+ Years, I have developed a wide range of skills that would meet and exceed the expectations for the role.

I would relish the opportunity to bring this level of success to your company. If you would like to get in touch to discuss my application and arrange an interview, you can contact me.

AREAS OF EXPERTISE


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Well versed with


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Language Skill

Language is absolutely central to your learning: without it, you cannot make sense or communicate your understanding of a subject.

  • English
  • Hindi
  • Malayalam
  • Tamil

My Exprience

11+ Years Exprience

Above and beyond my experience and capabilities I have been commended for my high level of interpersonal skills and my naturally engaging personality. My motivations include learning new things, the challenge of meeting the needs of an organisation, and ensuring high-quality outcomes.

Cy4

CY4 Digital Twin Product & Solutions Pvt. Ltd

As Project Manager
Dec 2023 – Present
Duration: 1 year 11 months



Key Result Areas:

  • Leading a team of 60+ engineers delivering digital twin and layout engineering projects.
  • Overseeing project planning, quality assurance, and team performance monitoring.
  • Managing onboarding, training, and workload distribution for new and existing team members.
  • Driving project coordination to ensure on-time delivery aligned with client expectations.
  • Handling billing, invoicing, and governance for multiple concurrent digital twin projects.
  • Coordinating with cross-functional teams to ensure seamless integration of design, simulation, and execution workflows.
  • Monitoring project risks and implementing mitigation plans to maintain delivery timelines and quality standards.
  • Reviewing digital models, layouts, and simulation outputs to ensure accuracy, compliance, and project readiness.
  • Streamlining processes by introducing best practices, SOPs, and workflow enhancements to improve team efficiency.
  • Collaborating with clients for requirement gathering, design validation, and periodic project reviews.
  • Ensuring adherence to organizational and client-specific CAD/BIM guidelines, engineering standards, and quality benchmarks.
  • Managing resource allocation across multiple projects to maximize productivity and reduce idle capacity.
  • Supporting digital twin implementation, including data integration, layout updates, and virtual factory validation.
  • Overseeing vendor coordination for scanning, modeling, and third-party engineering deliverables.
  • Preparing weekly and monthly progress reports for leadership review and performance assessment.
  • Facilitating technical training sessions to upskill team members on latest tools like Revit, Navisworks, and BIM 360.
  • Driving continuous improvement initiatives focused on reducing rework, improving accuracy, and enhancing delivery speed.



Projects:

  • Digital Twin Factory Model – Multi-OEM Projects – Led the development of large-scale digital factory environments integrating 3D layouts, equipment models, safety envelopes, and MEP systems using Revit, Navisworks, and ACC.
  • Scan-to-BIM (200,000 sq. ft Facility) – Executed complete point-cloud scanning, quality validation, alignment, and conversion of legacy 2D data into accurate 3D digital models for improved planning and simulation.
  • Ford Motors – Factory Layout Optimization – Designed and validated layouts for major installations, reducing clashes by 20% and improving factory space utilization by 15% through Navisworks simulation and MEP coordination.
  • Mercedes-Benz R&D (MBRDI) – Reverse Engineering & RFQ Standardization – Implemented structured RFQ templates, improved RFQ processing time by 15%, and resolved 95% of interferences through improved clash-detection workflows.
  • Caterpillar India – Space Reclamation & Ergonomics Improvement – Reclaimed 27,000 sq. ft of shop-floor space by redesigning layouts, conducting human simulation studies, and executing virtual build validations.
  • Digital Twin Implementation – CY4 – Oversaw end-to-end digital twin data integration, layout updates, virtual factory validation, and multi-disciplinary model coordination across multiple projects and clients.
  • Process Automation & Workflow Optimization – Introduced standardized SOPs, automated review workflows, and enhanced clash-resolution processes to improve accuracy and reduce delivery timelines by 10–15%.
AMS

(Deputed at MBRDI Pune) Advanced Mechanical Services India Pvt. Ltd.

As BIM Coordination Engineer
Apr 2022 – Aug 2023
Location: Hyderabad
Duration: 1 year 4 months



Key Result Areas:

  • Coordinated with suppliers for RFQs, quotations, and purchase orders through the BANF procurement platform.
  • Performed reverse engineering for laser-scanned models and validated them against company standards.
  • Ensured quality assurance of point-cloud data by checking noise levels, completeness, alignment, and accuracy.
  • Maintained and updated 3D BIM models (Revit, Navisworks, MicroStation) ensuring cross-disciplinary consistency.
  • Collaborated with design, MEP, and layout teams to incorporate changes into the federated model.
  • Conducted clash detection meetings, generated BCF reports, and coordinated resolution workflows.
  • Supported engineering change management by tracking revisions, documenting updates, and maintaining version control.
  • Verified vendor submissions and ensured alignment with OEM CAD/BIM guidelines and project specifications.
  • Facilitated cross-functional model coordination meetings between engineering, simulation, and facility teams.
  • Prepared As-Built models incorporating scan data, redline drawings, and engineering comments.
  • Produced model status reports, scan-progress reports, and quality-check documentation for project leadership.
  • Ensured seamless integration between point-cloud scans and ongoing design development.
  • Identified model inconsistencies, design conflicts, and missing data, and escalated appropriately.
  • Managed model-sharing workflows using BIM 360/ACC for cloud-based coordination.
  • Assisted in creating installation feasibility studies and equipment placement simulations.
  • Coordinated site visits with scanning vendors and ensured safety guidelines and scanning protocols were followed.
  • Validated geometry, tolerances, and model orientation for manufacturing and facility upgrade requirements.
  • Supported planning teams with accurate spatial data for layout feasibility and production line modifications.



Satven

SATVEN Engineering Services Pvt. Ltd.

Deputed at Ford Motors

As PLayout Engineer
Location :Chennai
Aug 2016 – Apr 2022
Duration: 5 years 8 months



Key Result Areas:

  • Prepared IFC, IFB, and IFD drawings per OEM CAD guidelines.
  • Simulated machinery installations using Navisworks and Process Simulator.
  • Designed factory layouts supporting new product launches and MEP coordination.
  • Performed clash detection using Navisworks and resolved interferences.
  • Modeled space, safety envelopes, and traffic patterns for manufacturing facilities.



CAT

Caterpillar India

As an Assistant Engineer
1 year
Location:Chennai
Duration: Apr 2015 – Aug 2016



Key Result Areas:

  • Conducted virtual design reviews, human simulations, and ergonomics studies.
  • Supported factory layout planning, MBOM validation, and process improvements.
  • Developed 2D and 3D factory models to enhance production workflows.
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CAREER ACHIEVEMENTS:

  • Reduced onboarding time by 15% through optimized training and workflow strategies.
  • Achieved 10% cost reduction through efficient workload distribution and resource planning.
  • Resolved 95% of all project interferences during the MBRDI project lifecycle.
  • Reduced project clashes by 20% through comprehensive digital clash analysis.
  • Improved space utilization by 15% via optimized layout engineering.
  • Reclaimed 27,000 sq. ft. of factory space through layout redesign.
  • Completed scanning of a 200,000 sq. ft. manufacturing facility and built corresponding 3D models.
  • Started my career as an Executive and rose to a Project Manager.



Education

My Educational Background

Annamalai University

Bachelor of Science in Mechanical Engineering

From Annamalai University

In 2008 – 2012

Training & Certifications:

  • Autodesk Revit Professional Training
  • Autodesk Navisworks Manage – Clash Detection & Simulation
  • AutoCAD / AutoCAD MEP Advanced Training
  • BIM 360 (Autodesk Construction Cloud) Workflow Training
  • Point Cloud Processing & Scan-to-BIM Training (FARO / Recap)
  • Factory CAD / Plant Simulation Training
  • MicroStation Professional Training
  • Safety & Quality Compliance Training (as per OEM standards)



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My Resume

Declaration

I hereby declare that the details furnished above are true and correct to the best of my knowledge and belief and I undertake to inform you of any changes therein, immediately.

Sathiaraj Rajendran

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