Engineer Manager

Ajay M. Kharod

**** ************ **.

Rochester Hills, MI 48306

(H) 248-***-****; (Cell) 248-***-****

Email: **********@*******.***

Objective: Principal Engineer & technologist with

materials/process/design/tooling background in developing

lightweight structural & exterior applications, for global

transportation & energy markets.

Experience:

Principal Consultant (3/2009 to current)

. Lockheed/Plasan team for DOD/ITAR regulated JLTV program/ Principal

Engineer for design of Carbon fiber structure/cargo systems & body.

. Program management/Tenneco/Diesel Particulate filter, thermally

regenerative technology.

. Sandwich construction/ composites design & crashworthiness of

underbody of electric/battery vehicles.

. Large Aluminum door concept dev. for market segment industry leader

passenger van.

Gibbs Amphibian vehicles: Auburn Hills, MI. /8-2008-1/2009. Body

Engineering & Composites Manager.

. Responsible for recreational, First responder, & Automotive

platforms.

. Design of Aluminum frames, Aluminum & composite body panels, &

Carbon fiber/E.preg/ sandwich construction & Aluminum hulls ranging

from 12ft up to 25 ft. length.

. Mentored 17 member engineering team in Catia V5/ Pro E for design.

. Developed SOWs, sourcing strategy, light weight solutions combining

amphibian performance, vehicle load cases, naval architecture, and

hydro dynamic & hydrostatic loads

Wipro Technologies: Troy MI/ 2/2007-1/2008/ Body Eng. SME & Mentor

. Auto Steel Partnership's FMVSS 216 compliance/ roof crush strength

for 2010, on B pillar less vehicle, optimizing to a hybrid design

with judicious choice of AHSS steels with tailor welded blanks.

. Led Wipro teams for Nissan Europe pilots of extended van Sliding &

French doors, Renault/Samsung/ Geometric team in Korea, & Eng.

Change Process for Ideal/Tomkins.

Padsa: Mexico/ 5/2006-3/2007/ Technical Director:

. Structural composites designs & new proposals to GM, CAMI, DCX,

Nissan, VW, Arvin Meritor, Standard Taxi & non-automotive companies.

Cost reduction for corvette Targa, fenders, involving Mg. /Carbon

fiber/HSSMC.

General Motors: Troy/Warren MI/ (10/93 to 5/06)/ Staff Engineer - Design

Release & Program management.

. Excellence in design engineering of composites over multiple

programs using 4 phase vehicle development.

. Lead large diverse & global cross functional teams, weekly program

reviews, SMT interface.

. Strong emphasis on timely decisions, anticipating issues, conflict

resolution, & team approach.

. A total PLM approach spanning the phases of AVDC/ concept

development/ validation/ launch/ field issue resolution & "lessons

learnt", and guided by the APQP process.

. Expert in Unigraphics, sketcher/ parametric solids modeling.

Extensive use of VAS (vehicle assembly structure), work flow

methods, Design In Context, Team center engineering.

. Structural calculations, SSTS, QFD, DFMEA, DFSS, PFMEA, DFM, DFA,

GD&T, Validation, DVP&R, managing crash worthiness, safety, NVH,

impact to meet federal & global standards.

. Managed all aspects of release documentation including E2, and five

phase issue resolution (PRTS).

. Vehicle launch & PPAP dealing with Pontiac, Flint, Arlington,

Oshawa, Silao, Fort Wayne, & Mishawaka plants for all full size

truck future and current product activities.

. Use of Taguchi Analysis/DOE /DFSS & lean manufacturing for success

on programs.

. Created/owned/authored industry first SSTSs for major subsystems.

. Imperatives management (Pc/Ic/Ms/IPTV) @ equal or better

performance, for value engineering.

. GMT. Avalanche/Escalade Ext. cost reduction task force & 2008 H2MCE:

Total cost savings of 5.0 million/ year on composite Flipper panel,

midgate redesign, materials change, & savings of 4.0 million/ year

in prototype parts & tooling for H2 front end & hood, latches and

handles design. (1/05 t0 4/06)

. Hummer Pick/up Truck, Program manager, design, H2 pick up/ endgate,

& hardware package for alpha design. ( 11/2004 to 7/2005)

. 2007/2008 H2MCE; Design & Release/ Tilt forward composite hood, with

integral fenders, front end, structurally bonded 7 panels, hinged @

front bottom, remote start feedback latch & secondary latches. (

2/2003 to 12/2004)

. DFSS project for front end fit, grill/hood/ fenders for Hummer tilt

forward hood. ( 2/2003 to 12/2004)

. H2SUT; Design & Launch Composite endgate.( 4/2001 to 4/2003)

. Hummer 3; Front & Rear closures, Plastics F/R fenders, Develop total

SOR, for sourcing, Allowable costs, Alpha design with attachment

scheme etc. (1/01 to 7/01).

. Lambda ( Acadia, Outlook, Enclave & derivatives) Program manager,

vehicle architecture; Front & rear closures, Concepts & alpha

designs on endgate, cargo cover, midgate, developed SSTS, SOR,

Imperatives balance, sourcing etc.(1/01 to 7/01)

. Avalanche/Escalade Ext. GM & Industry first, largest endgate, &

midgate systems in composites. Total design responsibility for SRIM

Inner, HSSMC reinf. SMC outer, assembly with cap, bezel, appliqu , &

hardware, lockable handle, body ornaments, lock cylinder, G/A

installed, fully painted & assembled endgate. Engineered EPDM load

floor mat for cargo area on SUT. Design comprehended the floor

height differences @ C/D pillars, water management, midgate

protection features, & continuous loading surface. Concept

development of lightweight toneaue covers, floor flipper panel asm.

(7/98 to 1/2001)

. GMT.800. Technology Development: SRIM Composite Pickup Box and

Tailgate for a full-size Truck (8ft and 6 ft) Overall Technical

Program Management for multimillion dollar pilot program involving

large steel and alternate materials multiple tooling, directed fiber

perform technology, injection units, molding equipment, and bonding

equipment, ext. level spatter coat development. Program objectives

to demonstrate three minute cycle times. Extensive resource

management with both U.S. and European vendors. (10/93 to 7/98)

. Program Design manager, GM/ Ford/ Chrysler Automotive Composite

Consortium: P/U box system. Lead efforts in structural analysis,

design & process development for cross functional/OEM team. (10/93

to 12/95)

Rockwell International, Troy, MI: (05/89-10/93); Advanced Eng. Program

Management

. Composite ranger tailgate, Advanced PN-96-composite P/U box,

. Under hood Components Product development i.e. Ford 3.0L, 3.8L,

1.9L valve covers, 3.0L front cover, along with sealing systems,

using engineering to design plastic products, processes, and

tooling variations. Use of CAE methods for flow modeling, warpage

prediction, FEA and structural analysis.

. Technology Development of Triaxial braiding process for high

strength composites, Structural RIM for high strength composites,

low density structural RIM, high strength Vinyl Ester SMC Ford PN-

38 P/U box, Ranger tailgate, Mustang bumper beams, Thermoset

injection molding using lost core for intake manifolds, Injection

compression molding for valve covers/body panels, Materials

development for valve covers, front covers, co-molded LDSRIM for

sunshade/head liners, Compounding & extrusion/compression molding

of glass filled PP for structural parts/GMT. Directed Fiber

Preform equipment & process development, SRIM braided box section

bumper beams for P/U trucks, Compression molding of Azdel/GMT.

DSM RIM Nylon Inc. Augusta, GA :( 02/88-05/89); Market development

Specialist

Transmatic Inc. Pontiac, MI: (9/85-02/88); Staff Engineer

Ceat Glass Fibers, Bombay, India; (02/82 to 01/84); Application & market

development Engineer

Continuing education:

University of Michigan: Symposium on Light weighting for automotive

vehicles; 2009

ACC/ SPE conference proceedings & Technical committee; (2008/ 2009/2010)

GM University (1994-2006)

UG for designing engineers, conflict management, 4 phase vehicle

program management, Product life cycle management, GM design studio

practices & styling, PD processes & change management, supply chain

management, Developing learning design validation plan, field issues

resolution, vehicle recall process & support, math model based design

verification & analyses, production part approval process (PPAP),

Failure mode analyses, Develop & lead product team & develop PDT master

timing, Develop process flow documentation, Statement of Requirements,

Master parts list, Create SSTSs &CTSs, Develop & maintain Vehicle

architecture, Structural analyses using FEA/testing, Develop key product

characteristics & interface documentation, Develop regulatory compliance

summary, Imperatives management.

Education:

MS Engineering Polymers/ Mech. Design, University of Massachusetts,

Lowell, MA 09/84 to 02/87.

BS/BS(Tech.) Polymers/ Mech. Engineering, University of Bombay, India

06/74-09/81.

A detailed list of my "Industry First Projects, Patents & Publications"

can be provided on request.

Contact this candidate