Product Development Six Sigma

Sameer Khan

Rochester, MI *****

+1-313-***-**** *********@*****.***

CAREER SUMMARY

High-performing Senior Leader with expertise in building/optimizing organizational processes, measurement systems, and strategy to maximize business results for global automotive OEM’s & Tier 1 suppliers.

Skilled strategist who transforms strategic plans into workable solutions for product roadmap and benchmarks performance against key operational targets/goals.

Six Sigma methodology expert with extensive scope of responsibility, proven success, and track record of delivering optimal results in high-growth environments, through initiatives that exceed operational targets and yield measurable outcomes:

-Operational improvements

-Cost reductions through improved process performance

-Productivity gains

-Reduced tactical-planning cycle time

-Reduced product-development time

Extensive experience in product design, electrification, architecture development, competitive intelligence and launch of vehicle systems and sub systems. Results driven professional, able to work effectively in teams or independently to meet or exceed business objectives, as well as customer expectations. Fluent in engineering management tools and processes, including Advanced Product Quality Planning (APQP), Bill of Materials (BOM), Production Part Approval Process (PPAP), Failure Mode and Effects Analysis (FMEA), Lean, and Design Verification Plan and Report (DVP&R). Professional with good working knowledge and understanding of manufacturing processes such as casting, machining, cold forging, metal stamping, and extrusions. In-depth knowledge of diverse aspects advanced analysis mechanisms and FEA/CAE systems.

AREAS OF EXPERTISE

Operational Process Analysis

Strategic Planning and Leadership

Organizational Design and Development

Productivity and Efficiency Improvement

Architecture Development and Launch

Systems Engineering and Integration

Project Engineering Management/Configuration

Multi-Site Operation/Coordination

Process Redesign

Lifecycle Management

Total Quality Management

Negotiation, Persuasion, and Communication

Training and Leadership Development

Decision Making

Vehicle / Component Packaging/GD&T

Continuous Improvement of Operational Processes/Standards

Change Release and Coordination

Cross-Function Team Leadership

Customer Interface and Satisfaction

Problem Resolution

Design for Six Sigma (DFSS)

PROFESSIONAL EXPERIENCE

Education

MBA, Michigan State University, East Lansing, MI 2018

MS, Mechanical Engineering, Lawrence Technological University, Southfield, MI 2010

BS, Mechanical Engineering, Osmania University, Hyderabad, India 2007

Employment

Analyzes problems effectively and makes appropriate decisions without missing deadlines or causing timing delays. Accurately and effectively predicts the outcomes of alternatives to solve problems; appropriately addresses the inter-relationships between issues. Effectively applies existing practices or processes to new work situations that result in higher quality work products with enhanced efficiency. Adapts to change, is open to new ideas, takes on new responsibilities, handles pressure, and adjusts plans to meet changing needs of different programs & teams

Personal

Seeks out and accepts feedback, is a proactive learner, takes on tough assignments to improve skills, keeps knowledge and skills up to date, turns mistakes into learning opportunities. Generates new ideas, challenges the status quo, takes risks, supports change, encourages innovation, solves problems creatively. Promotes mutual respect, is direct but tactful. Exhibits professional conduct in stressful situations and tries to alleviate tensions through clear & direct communication.

PROFESSIONAL WORK EXPERIENCE

American Battery Solutions, Lake Orion, MI Sep 2022 – Oct 2023

Director of Platform Engineering and Service

Leadership & Continuous Improvement

Champion Customer Satisfaction

Build strong customer relationships and represent the voice of the customer

Takes ownership of customers’ issues and follows problems through to resolution

Handle complex and escalated customer service issues

Use data, customer insights, and root cause analytics to address product and/or process improvements and present these to other departments and senior management

Build Strategic Partnerships by developing relationships with and negotiating contractual agreements with external service providers to support customer programs and end-of-life service providers.

Forecast headcount, and workload and ensure the team is staffed with skilled, passionate customer-driven team members

Manage department financial goals, analyze variances, and initiate corrective actions

Platform Engineering

Provide sustaining design engineering for existing products

Develop and maintain tools to measure and report delivered quality metrics

Improve manufacturing yield and achieve delivered quality targets

Improvements include changes to products and processes

Analyze field returns to identify the root cause and corrective actions

Complete root cause analysis and corrective actions for product and process failures

Use documented data-driven and structured problem-solving methods

Provide technical support for the resolution of product issues in the field

Provide Platform Engineering input and tasks required to support new product introduction (NPI)

Service

Ensure customer satisfaction with product performance and field service activities

Assign and schedule regional Service Technicians

Prepare and approve quotations for field service activities

Review and approve field service reports; provide complete and professional documentation to the customer

Responsible for after-hours and emergency 24/7 customer support.

Develop and maintain spare parts programs with cross-functional operations support

Develop and present training programs for key customers and stakeholders to be utilized at customer sites, industry events, and new installations

Warranty

Manage customer Return Material Authorization (RMA) process

Manage customer Warranty process

Develop and implement warranty processes and tracking, including process flow diagrams and call center scripts

Create Customer and Product Warranty documents

Develop and implement systems and tools including Web-based, telephone, and email to collect and capture customer satisfaction data and ensure resolution and tracking of customer concerns

EATON CORPORATION – eMobility (Power Distribution and Protection), Southfield, MI Sep 2020 – Sep 2022

Global Systems Engineering Manager/Verification & Validation Manager, New Product Introductions

Global engineering leader for eMobility Power Distribution and Protection products, responsible for staffing a team that develops customer solutions, scopes programs, and defines engineering resources necessary to successfully execute new product development programs. Responsible for all systems engineering and verification & validation activities on high voltage power distribution and protection product development programs, serving the electric vehicle market.

Lead the system engineering efforts to develop re-usable, modular, optimal cost, weight, and volume architecture solutions for automotive and commercial vehicle applications.

Develop, negotiate, and manage specifications and product requirements based on OEM and Eaton design team input

Support pursuit process with RFI, RFQ proposal development with cross-functional teams including supplier engagement and selection.

Chair internal design reviews at all stages of development and support gate reviews with customers.

Responsible for system level performance tests, with skills/knowledge in application & integration engineering, and capable of analyzing large sets of data to assess the best customer-oriented solutions and compliance to requirements

Standardized BOM process for entire organization across all product lines. Power Distribution and Protection BOM family owner.

Lead benchmarking activities for product line to understand competition and develop best-in-class architectures and technologies for differentiation.

Standardize process, workflow, and work product for all functions within the division.

Responsible for reviewing and approving mechanical & electrical designs, drawings, and engineering change orders at all product development milestones.

BORDRIN NEW ENERGY VEHICLE CORPORATION, Oak Park, MI Sep 2017 – Sep 2020

Engineering Manager / Performance & China Integration Lead:

Directed a large cross-functional team of engineers, designers, and managers globally for EV architecture development of interior and exterior - BIW, Closures, Bumpers, Hybrid Front End Module, Seats, Trim, Instrumentation Panel, Floor Console, Overhead Console, Door Trim & Lighting.

Lead Product Lifecycle Management for A to C segment vehicles from cradle to grave using Teamcenter. Led component part numbering system development/implementation.

Lead CAE team in China to deliver performance feedback for Vehicle Systems at each milestone.

Led engineering to develop Mixed-material architecture to meet vehicle requirements for the China, EU & US market

Vehicle Systems lead to deliver on cost, mass and performance targets for all parts and assemblies.

Managed Architecture Development of parts and assemblies for EV platforms.

Launched and curated cross-functional teams of product managers and functional managers to develop new team structure and dynamic goals, roles, and feedback cycles to drive team performance.

Conceived and led major initiative to establish strategic product excellence through innovation, benchmarking, and collaboration to earn support from executive leadership.

Develop robust and compatible joining techniques for an all-aluminum BIW & closures.

BOM family owner for Body Systems which constituted over 700-part numbers.

Responsible for ensuring all Vehicle Systems related regulatory requirements are met for the China, EU & US market.

Develop system/technical requirements and DV testing for Vehicle Systems

Ensure all Vehicle level testing is undertaken to meet internal and region-specific regulatory requirements.

Led integration of Chassis & Body Structure by providing interchangeable suspension selection that used components with flexibility to attach two different rear suspension vehicle architectures: Twist Beam Suspension or Independent Rear Suspension.

Develop milestone deliverables for design for architecture development. Lead team to ensure all deliverables are met with high quality and on time.

Responsible for creating Product Technical Requirements (PTR’s) for vendor selection, conducting design reviews, tradeoff studies and functional integration for vehicle systems.

Responsible for vendor selection and release of sub-systems on all Bordrin programs being developed in US.

Managed technical, financial, and manufacturing strategy for all systems and components.

Composed and presented design and manufacturing strategies to senior level executives.

GENERAL MOTORS, Vehicle Engineering Center, MI Nov 2015 – Sep 2017

Senior Advanced Vehicle Design DRE:

Generating and executing technical solutions for Structures to support new vehicle programs

Responsible for Product Lifecycle Management using Teamcenter

Providing technical leadership for advanced component or technology development

Led Integration efforts between interior & exterior to deliver robust engineering solutions.

Performing complex design analysis and evaluating engineering designs

Working cross-functionally to implement cost reduction, methods, and product improvements, and to support prototype and production build activities

Balancing business imperatives, including but not limited to cost, mass, complexity, and timing

Production engineering design release of structure components and subsystems

Communicating information to and from internal and external customer organizations

Staying abreast of relevant new technology and competitive products

Develop and apply new and existing technology for Design, Manufacturing and Engineering

Develop and coordinate Engineering designs and systems with manufacturing, analysis, other vehicle subsystems, vehicle development, safety, customers, and other functions.

Responsible for Body Structure integrity and compliance to GM technical and quality standards throughout the vehicle’s life cycle

FORD MOTOR COMPANY, Product Development Center, MI

Lead Design and Release Engineer - Structures May 2012 – Oct 2015

Led design and development for OEM programs. Coordinated design and release of parts and assemblies in Teamcenter. Ensured products meets function, quality, cost, and timing requirements. Interfaced with internal groups and OEM engineering to identify and resolve product packaging and design issues.

Led weekly ‘Team of 4’ meetings with Purchasing, Finance, cost estimating to create a project plan to obtain timely resolution to all problems related to design and sourcing.

Evaluated vehicle manufacturing plans and provided recommendations to optimize manufacturing strategy to eliminate new tooling investment.

Reviewed & approved development and verification testing results on prototype vehicles.

Evaluated and root caused test fleet and durability test vehicles for functional issues.

Provided technical support to global vendor tooling group to successfully resolve plant complexity issue with the supplier.

Coordinated implementation of safety countermeasures for SORB on Edge program to improve intrusion numbers. Implemented material upgrade allowing down gage to improve cost savings and Safety performance.

Lead CAE Engineer – NVH May 2011 – May 2012

Carried out FEA/CAE analysis using the latest components and techniques. Directed a team of technical professionals to meet or exceed program targets. Applied computer technology to mechanical engineering processes achieving improvement in quality and savings in time.

InDepth Engineering Solutions, Troy, MI Dec 2010 – May 2011

Project Engineer:

Performed linear and non-linear static, multi-body dynamics (MBD), optimization, fatigue and NVH analysis on wide range of vehicle components for automotive OEM's.

Praga Tools and Manufacturing, Hyderabad, India Aug 2006 – Nov 2007

Project Engineer:

• Implemented design drawing and Die tool cutting guidelines.

• Verified all dimensional issues with stack up analysis of Catia Models for Tool design.

• Supervised prototype development and implementation of tool verification for quality control

SKILLS/TRAINING:

PMI certified Project Management Professional (PMP)®– Expires June 2024

UL-CFSP Certification-Automotive Functional Safety and the ISO 26262: 2018 Standard – March 2022

Knowledge of robust engineering tools/methods – APQP, DFMEA, PFMEA, SPC, MSA, PPAP, Lean, DFA, DFSS, 5 whys, 8D, tradeoff studies, best practices

Product Lifecycle Management (PLM): Teamcenter / ARAS / Enovia

Data Analytics: Excel, Tableau

CRM: Salesforce (Sales & Service Cloud)

ERP: SAP, Plex

MS Office: Word, Excel, PowerPoint, Project, One Note

Change Management: WERS(Ford) / E-Squared (GM)

CATIA / UNIGRAPHICS / NX3 / IDEAS / VisMockup – Part review

HYPERMESH / ANSA / GENESIS / NASTRAN – Pre-process / Post-process / Analysis

VOLUNTEER EXPERIENCE

Community Service April 2010 - Present

Detroit / Troy / Rochester Hills, MI

HOBBIES / INTERESTS

Weightlifting, Travel, Tennis, Mentoring, Coaching

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