Six Sigma Product Development, CAE and Manufacturing

SHIVA GUMATE

248-***-**** · *******@*****.***

Product Development/Launch/Manufacturing · sigma MBB · Customer Satisfaction

Consistent top performer, with recognition for conceptualizing and implementing, new processes/methods to improve customer satisfaction. Certified Six Sigma MBB, with expertise in using DMAIC and DFSS methodologies, to deliver solid business results. Real change leader with experience in managing diverse teams including internal and external customers based on data driven decision making.

Core Competencies

Six Sigma MBB

Proven CAE Expertise

Vehicle Development/Verification

TVM (Total Value Management)

Quality/Process Control - Manufacturing

Product Design/Development

Customer Satisfaction

Supplier / Client Interface

Mentoring and Coaching

Awards & Recognitions

1995 Customer Driven Quality Award - Presented by President of Ford Motor Company, June 1995

1996 Customer Driven Quality Award - Presented by President of Ford Motor Company, June 1996

Thunderbird Vehicle Significant Award: Presented by Vehicle Engineering Manager, October 1999

Soaring Spirit of Thunderbird Award: Presented by Vehicle Chief Engineer, January 2000

LVC CAE Department Award: Presented by Department Manager, December 2000

Tier 1 Employee with 5 Consecutive Outstanding Performance Reviews Jul’95 – June 2001

Spirit of Mustang Award: Presented by Vehicle Chief Engineer, August 2001

US Patent & Trademark Office: Dual Rate Air Extractor for Interior Quietness (Pending) October 2012

11 Ford Recognition Awards: Mar’01 – Jan’2025

Technical Publications

"Constrained Layer Damping Material on Mustang Doors" 2006 Ford Global NVH Conference, Dearborn-MI

“Torsional Rigidity of 2002 Thunderbird Body Structure” 2000 Ford Global NVH Conference, Dearborn, MI

“Evaluation of Residual Stresses in Axisymmetric Bodies from Post-Grinding Deformation by Finite Element Method” 1992 SAE Aerotech Conference, Anaheim, CA

"High Confidence Performance Prediction To Improve The Vehicle Development Process" MSC Nastran World Users Conference, June 1995, Newport Beach, CA

Education

SIX SIGMA MASTER BLACK BELT · FORD MOTOR COMPANY – Dearborn, MI – 2022

DFSS BLACK BELT – BUSINESS · FORD MOTOR COMPANY – Dearborn, MI – 2008

MBA · Michigan State University – Troy, MI - April 2007

SIX SIGMA BLACK BELT · FORD MOTOR COMPANY – Dearborn, MI - 2006

M.S. MECHANICAL ENGINEERING · University of NEBRASKA – Lincoln, NE - 1991

B.S. MECHANICAL ENGINEERING · JNT University – Hyderabad, India – 1988

Professional Experience

Ford Motor Company – Dearborn, MI May 1992 – Jan 2025

August 2022 – January 2025: MBB – Bronco Wind Noise Sprint at MAP Vehicle Engineering

R&R’s: Lynchpin (MAP, PVT, WEBASTO, TEIJIN) for U725 Wind Noise Sprint team

Key Achievements:

Lead cross-functional team to brainstorm and validate an initiative to address quality and warranty concern related A-Pillar Sail component on Bronco product assembled in manufacturing plant. This task is still in progress as team validates concerns raised during prior trials.

Lead STA, D&R, WEBASTO and TEIJIN to incorporate Wind Noise SC’s in SCCAF to improve/sustain Wind Noise performance of Bronco Hard Top products.

Lead TDE and VOME to develop WBDM templates necessary to streamline SPC data sharing with vendors.

Took lead in working with VOME and plant to include SC points in VOW cell measurement system to improve/sustain MAP parameters that are crucial for customer perceived Wind Noise performance of Bronco 3 and 5 door HT products.

Worked with vendors and VOME to include audit points in VOW cell to monitor flushness of surface points that are critical for Wind Noise performance of Bronco vehicle.

April 2012 – July 2022: S&R VFG and TVM (Total Value Management) SME Vehicle Engineering

R&R’s: S&R SME for all TVM actions for Ford and Lincoln products, VFG engineer early warranty and prevent recurrence.

Key Achievements:

Key VE enabler for TVM actions resulting in over $300M in cost savings achieved without compromising customer perceived performance of Ford and Lincoln products.

Led team efforts to replicate TVM proposals on prototype vehicle for evaluations.

Assumed proactive role in facilitating TVM efforts to expediate evaluation efforts by using resource in United States, Mexico and Brazil.

Reviewed quality concerns related to S&R NVH of Ford and Lincoln products and worked with PVT and other stakeholders in addressing the concerns plants so that error states are corrected in plant mitigating quality concerns in field.

April 07 – March 2012: Design for Six Sigma Black Belt Vehicle Engineering

R&R’s: Use Design for Six Sigma discipline to develop and implement robust design solutions to address chronic vehicle issues affecting Interior Quietness of Ford and Lincoln vehicles.

Key Achievements:

Demonstrated leadership in working with various Ford organizations to identify and resolve chronic issued related to Interior Quietness TGWs of Ford and Lincoln vehicles.

Developed test methods/procedures to evaluate and validate CR/IR objectives of Dual Rate Air Extractor component. This patented industry first design is scheduled for implementation in forward model SUV and Crossover vehicles.

Trained vendors in measurement system analysis to ensure that quality of components supplied to assembly plants meets the engineering sign-off criteria.

Developed Design Rules, Migration Plans and secured buy-in from D&R management to implement them in upcoming vehicle program milestones.

Nov 04 – Mar 07: Mustang Manufacturing (PVT) Engineer Auto Alliance International (FRAP)

R&Rs: Customer Satisfaction, Quality/Process control, Warranty and change management for Wind Noise and Ride and Handling attributes of 2005 thru 2008 MY Mustang Coupe and Convertible vehicles.

Key Achievements:

Demonstrated over 40% improvement year-over-year in Wind Noise warranty performance. Overachieved on GQRS performance for Wind Noise attribute and achieved BIC status for 2005 through 2007 MY vehicles.

Led cross-functional teams in using Six Sigma methodologies to implement product changes to resolve issues and achieved 29% sustained improvement in vehicle sealing characteristic of Mustang vehicles.

Assumed a proactive role in identifying opportunities to reduce material and labor costs while improving and/or maintaining the current functional performance of the vehicle.

Led road map to achieve 125 CFM air leakage performance on Coupe vehicle. Took lead in resolving issues identified in FCPA & M10 evaluations on items affecting Wind/PT/Road Noise and Ride & Handling performance of the vehicle.

Aug 01 – Oct 04: Mustang Development Engineer Mustang Vehicle Engineering

R&Rs: Benchmarking Ford and competitive vehicles, target development, issue resolution, engineering evaluation, design verification plan for all new 2005 MY Mustang vehicle program.

Key Achievements:

Invented design solutions (using CAE tools) to significantly improve the rigidity of the S197 structure by 40% which resulted in 7% improvement in customer satisfaction for Convertible shake performance of Mustang vehicle.

Led vehicle development efforts of Road NVH attribute. Developed target strategy to optimize component level performances of Steering Column, Seats and other sub systems in the vehicle to achieve customer driven performance.

July 95 - July 01: Product Design CAE Engineer NA Car Product Design & Verification Department

Primary responsibilities: Lead NVH CAE Engineer NA Car CAE Organization. Conceptualized and developed efficient solutions to improve torsional rigidity of 2002 Thunderbird product. Provided effective and feasible design solutions to resolve Rear End bending issue on 1998 Lincoln LS product. Developed design solutions to support system level performance. Lead multi-attribute teams to develop analytical models for several vehicle programs. Trained and mentored engineers in the usage of new processes and tools.

May 92 - July 95: CAE Project Engineer On-Site Consultant @ Ford Motor Company

Primary responsibilities: Develop analytical models and provided design direction for body structure development. Performed design sensitivity analysis and optimize weight of vehicles. Developed joint models and assessed their performance to target. Conducted CAE vs Test correlation.

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