Manufacturing Engineer Project Coordinator

Sunny Bhogle

*****.******@*****.*** 437-***-**** linkedin.com/in/sunny-bhogle-738b3919

Summary

-Engineer with 20 years of versatile experience in the Automotive Industry.

-Strong team orientation with excellent communication & interpersonal skills working with project teams across the globe.

-Good exposure of assembly automation and testing systems working with various suppliers.

-Versatile Project Coordinator known for successfully executing diverse Project tasks to accomplish pending deadlines.

-Superior problem-solving and critical thinking skills, as well as a meticulous attention to detail.

-Worked across the globe in countries like Canada, China, Germany, Austria, Malaysia and India.

-Worked with renowned Automotive OEMs such Volkswagen, Tata Motors and Magna Steyr Engineering.

-Through Magna Steyr worked with various OEMs such as Daimler, Geely, Proton on New Product Launch Projects in Malaysia, China, Austria etc.

Experience

Launch Engineer – Electric Drive Unit Assembly

General Motors – St Cathatines Jan 2024 – Till Date

-Working with GM Central Manufacturing Engineering in the launch of Electric Drive Unit Assembly line.

Manufacturing Engineer – V6 Engine Assembly

General Motors – St Cathatines July 2022 – Dec 2023

-Identify bottle neck operations, improve throughput by reducing downtime, equipment cycle time and rejection (Throughput Improvement Process).

-Support the production team toward resolving issues with data and analysis (root cause analysis)

-Providing technical direction / information to skilled trades

-Support the implementation of product changes

-Process Documentation: PFMEA / Control Plan / Error proofing

-Drive cost reduction by reducing eg spare cost, energy saving etc

Achievements

-Improve performance on the piston bearing press station from 85% to 93% (Bottle neck station on Piston assembly line)

-Modify the design of the valve spring key insertion tool which significantly reduced the downtime and an annual cost saving of 18K

-Improve the performance on the automated piston stuffing stations by identifying alignment issues and working together with controls to fix repeated electrical faults.

Manufacturing Engineer

Deco Automotive - Magna International Nov 2019 - June 2022

-Responsible for OEE improvement on robotic MiG weld assembly lines for suspension cradles and robotic bushing assembly lines for these cradles.

-Review CMM and blue wrist data to analyze the variations in the assemblies.

-Get the changes in fixtures implemented through tool room.

-Implement and document engineering changes internal and external changes

-Participate in ergonomic committee meetings and implement design solutions that improve production efficiency and ergonomics

-Supervise equipment relocation and installation.

-Assist maintenance in identifying and resolving downtime issues.

-Assist in resolving quality concerns.

-Updates and documents current plant layouts.

Achievements

-180K annual cost saving by reducing the scrap on rear subframe bushing press line from 6% to 1%

-Relocation of robotic bushing line in a short duration of 2 weeks from Brampton to Etobicoke facility

-reduced downtime because of sensor failure and a 20k annual saving by implementing alternate sensors

Continuous Improvement Coordinator

Vinylbilt Windows & Doors Corporation Jun 2018 - Nov 2019

-Work with various departments to understand their operations and create workflow diagrams to clearly demonstrate existing business processes

-Utilize lean manufacturing tools to identify and develop solutions that drive operational improvements

-Document business & functional requirements and maintain business process

-Collaborate with the development team to optimize applications

-Analyze process and opportunities for continuous improvements

Manufacturing Engineer - Industrial Services

Magna Steyr India Mar 2011 - Mar 2018

-Major working on Simultaneous engineering projects / New product Introduction with Automotive OEM’s across the globe.

-Through Industrial services worked with various Automotive OEM’s such as at various global locations such as China, Malaysia, and Austria.

-Participate in engineering design review meetings and highlight product design concerns if any.

-Benchmark designs and raise engineering change request for assembly and quality improvement.

-Ensures correctness of engineering bill of materials and converting to manufacturing bill of material.

-Prepare assembly flowcharts and process documents.

-Conduct assembly feasibility of tightening tools in CAD for accessibility and ergonomics and prepare tool list for assembly.

-Prepare assembly line layouts or suggest modifications in AutoCAD based on the product design.

-Identify equipment required for manufacturing and prepare equipment specifications list.

-Identify equipment suppliers, discuss and finalize the specification of equipment. Designing equipment concepts (conveyor hangers, fixtures etc.).

-Coordinating with various departments for civil and utility requirements for the equipment installation. Installation, commissioning and proving of equipment’s together with the suppliers.

-Support prototype vehicle builds for process document verification and identification of assembly or quality concerns.

-Participate in the ramp-up meeting for presenting assembly tools / equipment readiness and highlight any concerns if any.

-Support the manufacturing team for new product introduction.

-Support sales team of preparation of technical offer document and capacity plan for various projects.

-Presenting prospective customers of the department capability and possible ways to support the various projects at the customer end.

Achievements

-Successfully implemented a low volume EV assembly line for Daimler BYD in Shenzhen.

-Lead Assembly team on various Simultaneous Engineering projects at Magna Steyr China and India.

MANUFACTURING ENGINEERING - VEHICLE ASSEMBLY

Volkswagen India Apr 2008 - Feb 2011

-Participate in 3P (Production, Preparation, Process) at Germany for the introduction of the new Polo.

-Define tentative assembly build sequence and stage wise work content.

-Supporting VW Germany planning team for the Greenfield plant setup by budgeting, planning of equipment, preparing equipment specification sheets and making technical comparison of various suppliers.

-Reviewing supplier equipment designs before manufacturing go-ahead (i.e. buy-off)

-Preparation of 3D Plant layout in Microstation.

-Co-coordinating misc. Civil & Fabrication activities required for the installation of equipment.

-Co-coordinating with the plant engineering team the input requirements for equipment such as compressed air, power, water etc.

-Supporting the installation and commissioning of equipment.

-Taking equipment trials with the pre-production vehicles.

-Create and track project schedules for equipment readiness to ensure a smooth introduction of new products on the assembly line.

-Participate in the design review meeting to understand the model year changes or part localization changes.

-Prepare budget required for modification required in the layout or equipment for the introduction of model year changes on the vehicle.

-Modeling concept layouts for plant / line expansion and reviewing with the management team.

Achievements

-3 new product launches from pilot hall build to final production wrap-up

-Successfully implemented a greenfield Final assembly line within a short duration of 18 months

MANUFACTURING ENGINEERING - VEHICLE ASSEMBLY

Tata Motors Aug 2006 - Apr 2008

-Study CAD (Catia) data of new model and create rough assembly sequence documents.

-Participate in design review meetings, highlight product design concerns and suggest possible solutions for resolution of the problem.

-Based on the new product design plan for new tools and equipment required for assembly.

-Preparation of equipment specification sheets and technical comparison from various suppliers.

-Develop and co-ordinate plant and equipment layout improvements.

-Co-coordinating misc. Civil & Fabrication jobs required in the manufacturing & services areas.

-Participate in the prototype assembly build of vehicles for ensuring that assemblies are possible as per the planned assembly documents.

-Coordinate and follow up for the smooth introduction of new product on the assembly line by ensuring equipment readiness and availability of process documentation.

-Provides support to assembly manufacturing for resolving quality concerns, process improvements and fabrication of line-side material trollies.

-Budgeting the capital equipment costs based on the upcoming projects.

Software Quality Assurance Engineer

Bentley Systems Mar 2006 - Aug 2006

-Create, execute and maintain manual and automated test plans.

-Detect, track and verify software defects.

-Communicate with developers and product managers to keep abreast of product enhancements and fixes.

-Support to marketing for specific user queries or projects.

Education

University of Mumbai

BE, Engineering Automobile 2000 - 2003

Mandar Polytechnic

Diploma, Mechanical Engineering 1997 - 2000

Contact this candidate