Suresh Kumar’s journey as an engineer is a testament to passion, perseverance, and adaptability in the ever-evolving automotive industry. From his early academic years in Chennai to leading engineering innovations at Bajaj Auto, his career has been marked by a relentless pursuit of excellence. Joining Bajaj Auto as a Graduate Trainee Engineer in 1990, he played a pivotal role in shaping manufacturing processes and product development. Over the decades, he has contributed to landmark projects, including the Pulsar, KTM engine components, and advancements in EV manufacturing. His story reflects the essence of engineering leadership—blending technical expertise with strategic vision to drive industry transformation. THE MACHINING WORLD EXPRESS magazine unveiled his journey of excellence through this exclusive interview-
Q: Could you start by sharing a little about your academic background? What motivated you to pursue engineering, and how did it shape your career?
Growing up in southern India, career aspirations were often defined by a few distinguished paths—medicine, engineering, or an entirely different field. While the world of Biology and Chemistry did not particularly captivate me, Mathematics and Physics always intrigued me. This natural inclination led me to pursue engineering.
My father, a civil engineer, served as an inspiration, but my parents gave me complete freedom to make my career choices. I completed my schooling in Chennai under the ICSE curriculum and later secured admission to the esteemed College of Engineering, Guindy, where I specialized in Production Engineering. This field, which integrates manufacturing, industrial processes, and mechanical systems, laid a strong foundation for my professional journey.
Q: Was there a pivotal moment or influence during your academic years that guided you toward the automotive industry?
During my studies in Production Engineering, I was exposed to diverse manufacturing domains, including machining, metrology, welding, casting, and industrial automation. The automotive industry offered the ideal environment to apply this vast spectrum of knowledge.
In hindsight, my foray into the automotive sector was more unplanned than planned. Bajaj Auto, a company with a remarkable legacy, was the first recruiter to visit our campus as a day Zero recruiter, and I was fortunate to secure a position with them. This marked the beginning of a transformative journey.
Q: You have had an illustrious 35-year career at Bajaj Auto. How did your journey with the company begin? Could you walk us through your early roles and learning experiences?
My professional journey commenced in 1990 as a Graduate Trainee Engineer at Bajaj Auto. Following a rigorous induction program, I was assigned to a specialized division dedicated to designing and developing cost-effective automation solutions.
This role was instrumental in shaping my technical acumen, exposing me to varied manufacturing challenges, and allowing me to collaborate with some of the most knowledgeable engineers in the industry. It was a time of immense learning, where I honed my analytical and problem-solving skills, gaining a comprehensive understanding of manufacturing processes.
Q: What were some of the initial challenges you faced, and how did you overcome them?
Like any young engineer, I encountered multiple challenges:
- Bridging the Knowledge Gap – Transitioning from academic theory to real-world engineering required a steep learning curve.
- Navigating Tight Deadlines – The fast-paced nature of the automotive industry necessitated quick decision-making and execution.
The key to overcoming these hurdles was maintaining an attitude of continuous learning, observing keenly, and absorbing knowledge from experienced mentors. Hard work, coupled with a willingness to adapt, played a crucial role in my growth. I have always believed that humility and curiosity are vital in one’s professional journey.
Q: Over the years, Bajaj Auto has undergone significant transformations. How have you contributed to the company’s engineering advancements and growth?
Bajaj Auto’s evolution has been remarkable, and I have had the privilege of contributing across multiple domains. My team and I have played a pivotal role in:
- Timely product developments and launches
- Addressing critical quality concerns with engineering solutions.
- Implementing cost-optimization strategies.
- Enhancing productivity through process innovations.
We have always aimed to exceed expectations and drive engineering excellence, ensuring seamless synergy between innovation and execution.
Q: Are there specific engineering milestones or projects that stand out as particularly significant in your career?
- Bajaj Pulsar Development: A defining moment in India’s motorcycle industry, where I played a key role in setting up the transmission manufacturing facilities.
- KTM Engine Components: Spearheaded the development of critical engine parts such as integral crankshafts and camshafts.
- Structural Innovations for fully faired Pulsar Models: Developed advanced manufacturing techniques of motorcycle frames for seamless aesthetic fit and finishes of the motorcycle.
- EV Production Expansion: Successfully doubled Bajaj Auto’s EV production capacity within four weeks without significant capital investment.
Each of these milestones represents a fusion of innovation, strategy, and engineering prowess.
Q: The automotive industry is undergoing rapid transformation. What key trends do you foresee shaping the future?
The automotive sector is evolving at an unprecedented pace. Key trends include:
- Electrification & Battery Innovation – The shift towards electric mobility.
- Advanced Materials & Lightweighting – Enhancing efficiency and sustainability.
- Smart Manufacturing & Digitalization – Adoption of AI, IoT, and automation.
- Alternative Energy Sources – Exploring sustainable fuel options.
At Bajaj Auto, we are proactively adapting to these changes, integrating advanced technologies, and ensuring our engineering teams remain at the forefront of industry advancements.
Q: As a seasoned industry leader, what attributes do you believe are essential for success in leadership roles?
Effective leadership is built on:
- Relentless Perseverance – Overcoming challenges with determination.
- Open-Mindedness – Being receptive to diverse perspectives.
- Rapid Decision-Making – Taking strategic yet timely actions.
- Continuous Learning – Staying updated with industry shifts.
- Empathy & People Management – Understanding and motivating teams.
A leader must inspire innovation, foster collaboration, and drive meaningful progress.
Q: Finally, what advice would you give to aspiring engineers looking to build a successful career in the automotive industry?
My advice is simple yet fundamental:
- Build a strong technical foundation and master core engineering principles.
- Develop cross-functional expertise in mechanics, electronics, and software.
- Stay adaptable and embrace emerging technologies proactively.
- Cultivate a mindset of lifelong learning and continuous improvement.
- Prioritize innovation, agility, and customer-centric thinking.
The future belongs to those who are curious, adaptable, and committed to excellence. Engineering is not just about solving problems—it’s about creating possibilities.