OBJECTIVE
To contribute in project management with technical aptitude for continuous business growth & professional career advancement opportunity by leading/managing the team for achieving the targets above & beyond
EDUCATION
Dec 1995 Master of Science (M.S.) in Mechanical Engineering, Western Michigan University, MI
Apr 1990 Bachelor of Engineering (B.E.) in Mechanical Engineering, Osmania University, INDIA
ACHIEVEMENTS (synopsis)
Global experience by leading team of Mechanical/CAD/Electrical(HW)/Software/Systems engineer(s) at off-site as well as in-house with strong collaboration
Leadership role at every position in project engineering, planning, tracking and change management
Worked with less/no supervision with ‘plan of action’ under high timing constraints & visibility
Involved & contributed to Sales, Purchasing, Supplier Quality, Customer Care and Finance targets
Over 10 years’ experience in Product & Design Engineering of Electronic Modules & Sensors, Power Electronics, Occupant Restraints, Audio & Infotainment Systems with emphasis on safety, fuel economy and comfort/convenience
Expert knowledge in vehicle systems/applications: i) Mechanical Components Design, ii) Feasibility Studies for Optimization, iii) Analyzing the CAD/Simulations for Failure-Mode Analysis, iv) Benchmarking and v) Cost Optimization
Mentored and coached new members/engineers on internal & external systems/process(s)
Supported BU targets and meeting performance indications (KPI) quarterly
Performed excellent project management critical skills by tracking 30/60/90-day plans, timing plan reviews & mitigation plans, collaborated with all stake-holders for ensuring accountability
Directly involved in RFQ process, VA/VE initiatives, change management and executive reviews
Over 5 years’ experience as Lead/Resident Engineer and single 'point-of-contact' in infotainment, chassis control systems and electronic modules design & integration with strong customer relationship
Author and technical lead of test specifications & test procedures for the qualification of mechanical, thermal, environmental and electrical hardware requirements by working with Technical Specialists
Critical problem-solving skills in root-cause analysis by using DMAIC (Six Sigma)/DOE techniques, statistical analysis, RSS/stack-up studies, performing simulation & FEA data analysis
Highly proficient in Design Know-How's, DFMEA/DRBFM, GD&T, Stack-up Studies
Strong automotive OEM experience as Design & Release engineer and change management processes
Communicated effectively with all inter-department and senior management by working proactively
PROFESSIONAL EXPERIENCE
08/12 – Present Project Lead, PANASONIC AUTOMOTIVE SYSTEMS, Farmington Hills, MI
Played key-role as team lead on new business pursuit(s) for technology readiness & implementation
Single point-of-contact to customer teams and improved customer relationship year-over-year by running PAT/PDT on all technical/timing/commercial plans/issues & agreements for closing timely
Highly visible role for compliance & certification of product for salability in EU region by managing all activities with ‘plan-of-action’ by cascading the daily tasks to stake-holders for successful completion
Worked with Customer Quality team for PPAP approvals, quality-metric reviews and 8-D reviews
Directly responsible and lead in review & release of i) specification requirements, ii) risk assessment, iii) BOM cost impact analysis and iv) timing plan reviews and proposals for customer buy-off
Developed project timing plans by tracking in 30/60/90-day reports during launch build(s) and engineering changes – by supporting project management team with mitigation plans with key role
On-site customer support during launch of overhead display(RSE) for GM K2XX program
Performed leadership role for vertical alignment with Design Engineering/Project Management/ Sales/Test Labs/Factories/Quality/Suppliers and Customer in achieving the quarterly results and KPIs
ACCOMPLISHMENTS:
Aligned global teams for winning exterior DLP projector business as single source for Ford AV program
Organized mechanical/electrical design reviews on PGU, PCB assy, Heat-sink(s), Chassis/Housings
Played lead-role during ‘stop shipment’ with internal tasks alignment and daily reporting to customer senior management by reviewing the technical data for successful closure of the issue
Built customer trust thru one-on-one reviews on i) specification updates, ii) change implementation plans, iii) part changes and releases, iv) customer expectations and deliverables within short tenure
Contributed and worked with Sales in preparing quotes and mountain charts for customer approvals
Trained and coached new members on internal procedures/processes as well as GM/Ford system procedures for the team to be successful during proposals, design & development and implementation
Conducted deep-dive 8D reviews with containment plans on electrical HW issues, EMC, mechanical assembly issues, software and system related issues for improving customer confidence at GM & Ford
Successfully achieved material cost savings, reduced ED&T costs and initiated avoidance of testing costs
Worked on trouble-shooting vehicle systems’ issues by running vehicle diagnosis & bench testing by using DET, CANalyzer, EQ tool, Config tool and so on
03/09 – 08/12 Project Engineer, ROBERT BOSCH TOOL CORP., Mt Prospect, IL
Project engineering experience in global bench-top power tools with innovation and continuous improvement for using the miter saws & table saws by meeting world-class safety, precision & accuracy
Technical lead on electric motor qualifications & power tool updates for qualifications Agency compliance and Safety regulations in NA/EU/CN regions
Successfully launched 8” miter saw tool upgrades with soft-startup motor, motor performance and branding updates ahead of SOP schedule for OTD (on-time-delivery)
Performed product market studies by working with marketing & distribution centers on top issues
Developed concept thru prototype introduction of sliding table mechanism for table saw
Cross-functional responsibilities to meet product performance, safety, agency, quality and cost targets
Proficient in BGN Bosch systems (NPDP process, RDBM, TTM, EC (ANDI) release, QFD, etc.)
ACCOMPLISHMENTS:
Established 'gross best concept' to assist in marketing product decisions by conducting 'in-depth' bench-marking study & workshop on cost estimation & analysis of motors, miter saws
Created ‘easy-to-use’ calculators for cost estimation to minimize errors during benchmark studies
Improved quality by reducing warranty costs by improving 3-pt linkage system blade guard function
Written knowledge-based WiKi articles on design principle(s) of sliding table mechanism, most accurate measurement method on saw blade stopping time AND low-cost design solution on blade stopping time
12/07 – 01/09 Vehicle Evaluation & Verification Engineer, FORD MOTOR CO. (contract), Dearborn MI
Key role in managing low speed impact testing per US Part581/CMVSS215/GCC and Ford req’s
Responsible for program sign-off for bumpers & dynamic seals all Ford car & truck programs
Managed activities of vehicle and bucks timing plans, scheduling the tests and vehicle sign-offs
Reviewed the test data/results for requirements (NVH, Durability, Corrosion, and Dust/Water Ingress)
Improved procedures for consistency, accuracy in verification of bumper systems and dynamic seals
Constantly maintained high standards for achieving 100% FESO to meet GPDS deliverables in eFDVS
ACCOMPLISHMENTS:
Assisted design teams in resolving critical issues by optimizing testing methodology & troubleshooting
Improved the test setup & methods for standardization across testing facilities, product-line
Achieved more than $400K in cost avoidance + $222K in testing & prototype efficiencies
Developed 'Best-in-Class' sun-load test method per MIL-STD-810/DIN 75220 to simulate solar spectrum using metal-halide lamps for standardization and cost savings
07/06 – 12/07 Lead Design & Release (Resident) Engineer, MICROHEAT Inc., Farmington Hills MI
Lead development & implementation of heated washer fluid module/HWFM from cradle-to-grave
Liaison with direct customer interface on all Ford programs by reporting to V.P. of Engineering/Quality
Developed next generation of heated wash module by improving the performance, safety, integration with electrical wiring & LIN communication and optimization for 'in-line' connection with wiper systems
Technical lead/author of engineering specification to meet the regulations and customer requirements
Presented design proposals to customer by resolving critical packaging issues followed by feasibility studies by working with cross-functional teams in highly visible projects
Involved in bench-marking, retrofit the vehicles with heated wash system for customer vehicle reviews
ACCOMPLISHMENTS:
Key player in acquiring new business per migration plan by addressing critical packaging issues timely
Lead team of designers, mechanical/electrical group and R&D group during product development
Developed project timing plans for engineering, quality, manufacturing, testing per customer milestones
Author of Boundary Diagram, Interface Analysis, P-Diagram, RCL/RDM, D/PFMEA, DVP&R
Improved the efficiency of operational modes for lowering power consumption and fuel economy/CAFÉ
Worked with test lab technicians, prototype shop technicians on day-to-day task assignments
08/05 – 07/06 Product Engineer, TRSI, Auburn Hills MI / E-Motors & Power Electronics, Troy MI
Responsible for design, vehicle packaging for Hybrid Vehicle Power Electronics & Inverters
Experience on simulation studies for weight reduction & structural rigidity by material selection
Performed critical studies for assembly & manufacturing, durability and NVH using FEA studies
Designed battery tray and module brackets using CATIA v5 and released parts in VPM/TCE
Worked as passenger airbag engineer for Chrysler programs from ‘cradle-to-grave’
Developed & launched new airbag cushion (NCPM) from concept-to-production and certification
Worked w/crash & systems group in analyzing the crash data & films and proposed counter-measures
Applied strategic methods in tuning the cushion/tethers/vents/bag fold(s) for achieving LRD compliance
Supervised the teams during prototype build(s) of bag stitching/folding/assembly/electrical checks
ACCOMPLISHMENTS:
Resolved packaging challenges for HEV program: i) Inverter, ii) DC Converter, iii) Traction Motor and Power Electronics Controller design using CATIA under high-pressure timing constraints
Worked closely with FEA simulation group on a) thermal management studies, b) structural FEA
Key role in material selection, BOM preparation, drawing creation w/GD&T, tooling reviews
Contributed to FIVE STAR rating with successful compliance testing using new airbag cushion design
Improved PAB door fit/finish, quality/customer satisfaction by proposing cost effective solution
Special projects on: i) Welded metal bracket crack during vibration testing, ii) GD&T for tooling updates
03/00 – 08/05 Design & Release Engineer, FORD & TEXTRON (contract), Dearborn MI
Responsible for design & release of seat belt components & OCS for small SUV & hybrid
Developed integrated door-panel concepts, instrument panel and interior soft-trim components
Responsible for containment & corrective actions (8D,6-panel) by reporting to vehicle line Director
Project leader of major seat assembly & OCS changes to seat frame/mechanism/foam/trim and STPS
Worked in Mustang program management/Interior systems by managing all program activities for launch
Used DOE approach for addressing molding & part finish issues, verified thru cold & hot deployments.
Textron: Supported interior cockpit launch on Ford/Lincoln luxury sport utility vehicle
Responsible for the integration and act as liaison between customer and suppliers during development
Designed rear window and trim parts for new vehicle program in CATIA v4 with full design support
ACCOMPLISHMENTS:
Performed DOE studies to resolve the molding issues of airbag door for fit/finish & quality requirements
Accomplished 6 to 7 million USD cost savings (MCR) for 2002 & ’03 and improved TGW’s & R/1000
Achieved program cost targets by resolving major design & packaging issues to meet new regulations
Major accomplishment in resolving 'wire-chafing' and 'squeak & rattle' issues of steering-wheel assembly
Implemented 'faux' door insert concept for door-trim by improving quality/appearance for cost savings$$
HONORS/CERTIFICATES/AFFILIATIONS
Since July 2019 Club President (Panasonic FH Toastmasters Club)
Since 2013 HIGH 5 Recognitions (Untiring Effort for Improvement AND Cooperation & Team Spirit) by peers & management Oct 2010 Bosch SQJ Recognition (runner-up & winner for two consecutive months)
Oct 2008 Employee Recognition Award (nominated for 2008 VEV Achievement Award), Ford Motor Co.
Jun 2002 Inventor and U.S. Patent Recipient (US 6,408,712 B1)
Oct 2001 Green Belt (Six Sigma) Certified
Jan 1992 Certificate of Proficiency Recipient, Bharat Dynamics Ltd., Ministry of Defense, Government of India
2015 – ’17 Lead/Head-coach of ‘All Girls’ Robotics FTC team (2yrs) for Middle School Students
Present Member of W.M.U. Alumni / Volunteer work at Community Services & Outreach activities
COMPUTER/SYSTEMS’ SKILLS
Diagnostics & Communication Tools Vector Tool, DET, CANalyzer, EQ tool, Config tool
CAD/CAE/CASE Tools ProE/Intralink, CATIA v4/v5, MSC PATRAN 8.0, Maxwell EM 2D/3D, VPM/TCE
Engineering/Release Systems W.E.R.S., Vis Mockup/Digital-buck, eFDVS and Ford engineering release systems
GPDS/VDS, E-squared and GM engineering release systems
Desktop Applications Microsoft Office Professional, Microsoft Project, Lotus Notes
Operating Systems Ms-DOS, Windows 10/Vista/NT, Mac, Sun OS/Unix, AIX, NEXT