Project Management Product Development
Resume:
Dynamic Engineer with Expertise in Vehicle Product Development, EV Technology and Aerospace engineering design. An accomplished engineer with extensive experience in fast-paced, agile environments, driving innovation and excellence in commercial vehicle product launches. Skilled in overseeing the complete lifecycle of exterior components and accessories, from concept through implementation, with a strong focus on problem-solving. Specialized in electric vehicle engineering, utilizing cutting-edge technologies to deliver pioneering solutions. Proficient in design and development, prototype development, and project management. Expertise includes CAD (Siemens NX, Catia V5), PDM/PLM, TCE, DFMEA, and IQ-FMEA. Strong analytical skills with experience in GD&T, 7QC tools, DMAIC, DFSS, and change management. Certified in Project Management, PDM/PLM, 7QC (6 Sigma), IQ-FMEA, Agile Methods, Decision Making, Proven ability in managing teams and leading projects, achieving an 18% increase in design speed. Recognized as a 'Most Valuable Performer' for making a significant overall impact through strategic leadership and analytical prowess.
Led the mechanical design and development of virtual and augmented reality hardware, focusing on AR/VR headsets. Designed Plastic & sheet metal components using Siemens NX, ensuring manufacturability & durability.
Collaborated cross-functionally with electrical, thermal, and optical engineers to integrate complex systems into compact mechanical designs. Managed prototypes & testing on VR and AR components, validating designs against thermal, stress, and fatigue.
Created and reviewed detailed 3D models and 2D drawings for components, including AR glass, cable routing, and PCB packaging, following industry standards and best practices.
Performed thorough packaging studies, ensuring effective integration of PCB boards, sensors, cameras, and cables within AR/VR devices, while adhering to ergonomic and aesthetic requirements.
Applied rigorous DFMEA and IQ-FMEA methodologies to ensure product reliability & to mitigate potential design risks.
Led the project through multiple development phases, collaborating with suppliers and ensuring alignment.
16 Years OEM Experience - Expertise in Automotive Vehicle Structures With 16 years of OEM vehicle manufacturing experience, I possess in-depth knowledge of automotive vehicle structures. I have successfully managed product launches for both commercial vehicles and passenger cars, overseeing the entire process from body engineering, air-actuated component to product validation and final launch.
Greenfield and BIW & Exteriors
With a strong foundation in engineering principles, successfully led complex, led the development of front and rear body structural components. Cross-functional projects across sectors, including electric vehicles, Greenfield developments, and advanced BIW and exterior component design. My technical expertise and strategic approach empower me to solve challenging engineering problems and drive innovative, results-oriented solutions.
Experienced in High-Volume Interior trims.
Design and Release including door panels, instrument panels, floor consoles, and headliners, focusing on structural integrity, aesthetic alignment, and manufacturability. Collaborated with CAE engineers to interpret simulation results, making data-driven adjustments to improve strength, durability, and fit. Integrated CAE recommendations into designs to enhance overall product performance and meet safety and quality standards.
Leadership in Electric Vehicle and Exterior Projects I have led cross-functional teams to successfully launch electric vehicle (EV) exterior components such as bumpers, door extensions, and footsteps. My responsibilities included creating quality gate schedules, mitigating supplier risks, and ensuring on-time product launches, while adhering to high standards of quality. Experienced in closure assemblies with a focus on window glass, windshields, heated windshield, weather sealing’s and sash components, which complements my understanding of door integration, interfacing with E&E components, routing and fitment for interior applications.
Skilled in designing and detailing components using NX for both 3D modeling and 2D drawings, specializing in creating complex sheet metal and plastic parts such as brackets, panels, and trim supports. Worked on optimizing interior component packaging to ensure seamless integration of parts like latches, fasteners, and mounts.
Supplier Coordination in the development and refinement of interior components, supporting prototype, production build events. Design updates to align with vehicle development milestones and to ensure parts are production-ready. MADHAN KUPPUSAMY
Engineering Manager
*************@*****.***
Bellevue, WA, 98004
EXECUTIVE SUMMARY
EXPERIENCE
DIVISIONAL MANAGER ELECTRIC VEHICLE, R&D
DAIMLER TRUCKS INDIA & JAPAN
JUL’ 2008 – JAN’ 2014 & JUN’ 2019 – JAN’ 2024
MECHANICAL ENGINEER V AR/VR, HEADSET
ICONMA, L.L.C. for META – Redmond, WA I USA
MAR’ – APR’ 2024
Problem-Solving and Field Failure Prevention
Using tools like 7QC and comprehensive 8D reporting, I have consistently resolved complex field issues. These efforts have led to practical, preventive solutions to challenges such as door noise and design flaws, significantly improving product performance and reliability.
Innovation, Prototyping and Process Improvements Successfully patented my innovative ideas into reality. I developed an incubation lab focused on design, prototyping, and fitment checks, which has reduced design iterations and lead times. This initiative was recognized internally for its cost-effective approach to innovation, helping to streamline product development cycles. .
Body Structure Optimization: Ensured body structures met design guidelines and specifications, executed VA/VE projects to reduce body structure costs by decreasing weight and eliminating unnecessary weld points and beads.
Multi-Disciplinary Group Leadership: Led multi-disciplinary teams to achieve project objectives on door trims, exterior bumper trims, and interior trims, solving complex problems with high attention to detail.
Project Management & Analysis: Managed large, complex projects by breaking them into manageable components, developing recommendations and countermeasures, and collaborating with manufacturing engineering to align with key program indicators (KPIs). Design review and modification using CAD – Catia V5
Budget & Schedule Management: Proactively managed budgets, schedules, and technical requirements, provided technical leadership, and reviewed reports and plans to ensure alignment with project goals.
Airbus A320/A321 Deck Structure Fixtures: Managed design projects for Airbus A320 and A321 deck structure fixtures, ensuring solid validation and execution plans to meet quality and risk reduction goals. Creating CAD models for space flight hardware Aluminum structures, aircraft components and its assembly and welding fixtures.
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Vortex generator to reduce drag co-efficient, File # 2021P00494
Foldable double berth integrated with cabin cooling insulation for fuel efficiency, File # 2021ID02371
Pedals obstruction evictor
2005- 2006 Employee of the year, Best client coordination
2009 Employee of the year – (Award for Individual contribution towards excellent team orientation)
2013 Long-term performance
2020 Most Valuable Performer
PROJECT MANAGEMENT ENGINEER VEHICLE ENGINEERING, BODY INTERIORS SEGULA TECHNOLOGIES FOR FORD GMBH COLOGNE, GERMANY JAN’ 2014 – APR’ 2015
SENIOR PROJECT ENGINEER MANUFACTURING ENGINEERING, BODY-IN-WHITE ANADOCS IT SOLUTIONS FOR ROHTECH GMBH RAVENSBURG, GERMANY JUL’ 2006 – APR’ 2008
ACADEMIC EDUCATION
Master of Business administration, MBA
University of Madras Chennai, India
Oct 2005 - Jan 2007
Post Graduate Dip. In Plastics Engineering, PGD-PE Central Institute of Plastics Engineering and Technology Chennai, India Jul 2003 - Jan 2004
Bachelor of Engineering in Mechanical, B.E Mechanical University of Madras Chennai, India
Jun 1999 - Jan 2002
PATENTS
SKILLS CERTIFICATIONS
Project Management PDM/PLM – Smaragd CAD –
Siemens NX CAD - Catia V5 7QC (6 Sigma) DC
Weld IQ-FMEA Quick win for Efficiency - Agile
Methods, Decision Making Inclusion in Mind ISO- 14001 Environmental Management ISO 50001 Energy
Management ISO-TS 16949-2009 & IATF 16949 -
International Automotive Task Force
Design & Development Prototype development
Project Management Supplier Management CAD
- Siemens NX CAD - Catia V5 R&D Tool Kit
PDM/PLM, TCE DFMEA IQ-FMEA GD&T 7QC
DMAIC DFSS Change Management Quality
Function Deployment (QFD) Innovation Process
Automation Technical documentation
APPRECIATIONS
DESIGN ENGINEER VEHICLE ENGINEEIRNG, BODY AND EXTERIORS AKKA GMBH & CO. KGAA SINDELFINGEN, GERMANY
MAY 2015 - MAY 2019
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