Program/Project/Engineering Management

Raman R. Shetty, MSME

*** ******** ***** ********, ** 13031 H: 315-***-**** C: 315-***-**** ***********@*****.***

Profile: Program / Engineering Management

Over 20 years of progressive engineering program, project, and operations leadership delivering operational excellence and successfully managing critical programs.

Career marked by managing and optimizing multi-site, start-up, and offshore manufacturing operations. Background includes engineering and program management roles at Chrysler, start-up gear manufacturing firm Himalayan Automotive Technologies, GE Transportation and Borg Warner Automotive. Deep expertise in powertrain/driveline technologies to improve fuel efficiency, emissions and performance.

Deep experience in lifecycle project/program management, encompassing scope development, requirements definition, planning, and product development, prototyping, testing, and new product launch. Drove down costs, reduced obsolescence, and improved productivity by introducing Lean Six Sigma processes, and manufacturing best practices. Managed multimillion-dollar budgets, cross-functional teams, and multiple production areas. Trained in Lean Six Sigma.

Key Highlights

Instrumental in securing and managing $120M engine systems project

Established offshore, overseas manufacturing facility in India for automotive axle gear production.

Executed and led company’s first complete PPAP ahead of schedule and under budget.

Managed company’s first and only two programs designed, developed, and launched as complete systems with joint partnerships in Hybrid and AWD technology.

Demonstrated broad-based strengths and accomplishments in:

Program & Project Management Multi-site Operations Management Change Managment

Lean/Six Sigma Principles Kaizen/Continuous Improvements Quality Control & Assurance

Supply Chain Management Product Design & Manufacturing Strategic Business Planning

Customer & Vendor Relations Staff Development & Coaching Budget Planning & Control

Professional Experience

Borg Warner Automotive Corp. – Ithaca, NY July 2014 – March 2015

SENIOR PROJECT MANAGER / TECHNOLOGY MANAGER (Position Eliminated)

Recruited as senior project manager/IPT manager in the advanced engineering group to support the identification, product development and proof of concept execution of new technologies and products to support the Morse TEC product line of customized solutions for variable cam timing, chaindriven engine timing systems, and engine valvetrain and solenoid applications. Leverage deep automotive industry knowledge, strong engineering principles, project team management skills and business application acumen to support the development of new products.

Manage formal project management life cycle including customer interfacing, roadmaps, pricing, PIP Stage – Gate reporting, KPPs (development and management), budgets, resource allocation, NDA’s, POs, SOW, and IP management.

Supported pre-sales efforts by designing and presenting solutions for engine system product to a European OEM that resulted in securing $120M multi-year project.

Worked with supply chain and advanced manufacturing to beat competitor’s pricing by almost 13%.

Served as Senior Project Manager overseeing team of 15 internal and outside consultants through the full project life cycle including managing the requirements definition and clarifying goals with customer’s sales and engineering teams.

Beat cost and financial targets delivering 20% ROI & 15% profit.

Demonstrated basic function, performance and reliability of a CVVL (Continuous Variable Valve Lift system).

Recognized as value contributor to ideation sessions to identify product and market opportunities.

GE Transportation, Inc. – Erie, PA January 2013 – July 2014

ENGINEERING LEADER / TECHNOLOGIST

Recruited to lead the design, analysis and enhancement of drivetrain components for Off Highway Vehicle (OHV) propulsion systems and locomotives. Oversee 6 Engineers through the full project life cycle. Review specifications and develop engineering plans including design, development, testing & validation. Serve as Subject Matter Expert collaborating with manufacturing to ensure adherence to specifications, costs and quality standards.

Saved thousands by reducing waste and improving the manufacturing process.

Noted for exceeding goals for quality, cost controls and production times.

Himalayan Automotive Technologies, Inc. – New Delhi, India July 2006 – October 2012

DIRECTOR OF ENGINEERING OPERATIONS

Established and directed all operations for start-up gear manufacturing facility in India. Traveled frequently to coordinate start-up activities encompassing local, state, and federal licensing, process and procedure development, and vendor sourcing. Managed $1.2M start-up budget and built/led team of up to 20 consultants, engineers, and support personnel. Led design of tools, fixtures, PFMEA, control plans, and tool/op sheets. Interfaced with customer to track APQP activities and report production status.

Opened offshore, overseas manufacturing facility by selecting/acquiring land, contracting design and construction project to local architects and builders, and partnering with consultants to design facility layout, process flow, and production capacity.

Secured ten-year contract with $5M in first-year revenue growing to $10M annually by delivering successful competitive proposal and technical presentation to manufacture truck axle components.

Obtained verbal commitment for $60M in new programs over next ten years from several OEMs.

Contributed to M&A activities by conducting due diligence and participating in negotiations.

Chrysler / New Venture Gear/Magna Powertrain, Inc. – East Syracuse, NY

ENGINEERING PROGRAM MANAGER/PRODUCT TEAM LEADER (July 2002 – June 2006)

Promoted through five positions at New Process Gear Division to direct new product launches, continuous process improvements, cost reduction, VA/VE, warranty reduction, quality improvement, Poka Yoke, and design change initiatives for $200M division. Coordinated concept design, prototype build, and testing for advanced engineering programs. Tracked APQP with customer and component suppliers. Reviewed DVP&R, DFM/DFA, DFMEA, PFMEA, control plans, and tool/op sheets. Guided cross-functional team of 150+ engineering, sales, purchasing, supplier quality management, manufacturing, finance, production control, and production personnel. Facilitated customer, team, supplier, and launch meetings. Managed $15M+ in combined budgets.

Launched 200+-component geared product (MTX) for Chrysler small car platform one month ahead of schedule and 10% below $14M budget, gaining recognition for company’s first on time PPAP completion.

Nearly eliminated obsolescence costs (95% reduction) by initiating major design change on complex new product, mentioned above.

Boosted productivity 35%, while reducing scrap 5% by spearheading automation of component machining line.

Delivered $2M-$5M in annual cost savings by coordinating, implementing, and tracking multiple design and process cost reduction initiatives.

Lowered cost of new transaxle by 8% through supplier negotiations, in-plant process optimization, and detailed cost analysis on all components.

Reduced warranty costs 57% by managing multiple issues on current production manual transaxles.

Cut test buck rejects by 90%, lowered reject inventory costs by 10%, and reduced rebuild labor costs by nearly 80% through error-proofing / Poka Yoke of assembly line.

Led plant to secure TS16949 certification by leading division to pass audit on first attempt.

Chrysler / New Venture Gear

ENGINEERING MANAGER (April 1998 – June 2002)

Managed product design, development, and launch support of AWD and hybrid technology systems for Saturn Vue SUV, Ford Cobra R, Ford Saleen Mustang, and DaimlerChrysler minivan. Advised entire organization on all hydraulic and lubrication systems. Led multi-site team of 12 engineers in New York and Michigan. Created, managed, and tracked $4M-$8M annual budget.

Designed, developed, and launched first successful and complete driveline system with a hydro-mechanical torque biasing axle module in joint partnership with Ford Visteon. AWD system consisting of PTU, prop shaft, center bearing, torque biasing axle and half shafts was state-of-the-art and for GM Saturn SUV.

Partnered with DaimlerChrysler AG to jointly design and develop hybrid system for European minivan.

Designed, developed, and launched torque biasing differential in two years against average four-year driveline product cycle.

Reduced warranty claims 20% by improving processes on current production hydraulic systems.

Additional Chrysler Corp. Experience: Senior Product Engineer (1997-1998) NVH, FEA & Gear Development Supervisor (1994-1998) Gear Development/NVH Engineer (1990-1994) FEA Analysis, Design, and Development Engineer (1989-1990)

Education

New Jersey Institute of Technology – Newark, NJ

Master of Science in Mechanical Engineering (MSME)

New Jersey Institute of Technology – Newark, NJ

Master of Science Degree Program in Computer and Information Science, completed 30 credit hours

Manipal Institute of Technology – India

Bachelor of Science in Mechanical Engineering (BSME)

Publications

“Progressive Traction Control for Automotive Differentials.” SAE, September 2000. Presented at Fall 2000 Truck & Bus Show and 2001 SAE Show.

“Gear Noise Development using Dr. Taguchi’s Tolerance Design of Experiment Approach.” Society of Automotive Engineers (SAE), February 1992.

COMPUTER SKILLS

Proficiency with Excel, PowerPoint, Project, Outlook, CATIA, I-DEAS, C, C++, & NASTRAN.

Contact this candidate