Project Management Lean Manufacturing
Resume:
SENIOR LEADER
Innovative product engineering, LEAN manufacturing, and APQP gate management program leader. Expertise in leveraging data-driven analytics to support the delivery of systems and managing benchmarking and SKU rationalization to optimize KPIs. Success in leading process improvement to capture cost savings and maximize profitability. Possess exceptional business, technical, and problem-solving capabilities, strong leadership skills, and vast international business experience.
SIGNATURE STRENGTHS
Process Layout & Optimization
Product Design & Engineering
Financial budgeting, Roadmap & Reporting
Product Cost & BOM Oversight
Cross-Functional Collaboration
JIRA, Confluence, Atlassian, Perfect Pro Cal
Contract Negotiations
International Travel
Program Management
Solutions Design
Revenue Growth
Gate Management
LEAN Manufacturing, Kaizen, VSM
Staff Leadership & Development
Structural Problem Solving
Timing Plan Management per APQP
Regulatory Compliance
Tool Engineering
Project Scope Management
Competitive Analysis
Business Development
Thermal Management Products
Automotive LED Lighting
Flexible, Adaptable
PROJECT MANAGER, UFI FILTERS, TROY, MICHIGAN. JUN 2021 – MAY 2025.
Successfully launched electric drive motor (EDM) transmission cooler, water cooled condenser (BEV) for Stellantis and working on the launch of derivatives. Lead the design industrialization, OTOP, PV of Engine Oil Coolers for General Motors. Collaborations with cross-functional stakeholders, including engineering, manufacturing, purchasing, customers, and suppliers to achieve APQP milestones, ensure KPIs, Gate Management & Reporting.
PROGRAM MANAGER, BODY EXTERIOR LIGHTING. MARELLI, AUBURN HILLS, MICHIGAN. OCT 2016 - JUN 2021.
Lead the design and development of exterior lighting across a variety of vehicles. Partnered with cross-functional stakeholders, including engineering, manufacturing, purchasing, customers, and suppliers to achieve all program milestones.
Managed the full design and development lifecycle for exterior body lighting programs with contract values of up to $100M.
Oversaw all aspects of an initiative from contract award through design, development, industrialization of 2022 Ford P702BEV F150 forward lighting.
Launched 2021 Dodge TREX headlamp, a derivative of an existing production component. Also launched a derivative for use in Australia.
Championed the full lifecycle associated with the development of the 2022 Jeep Wagoneer headlamp – from contract award to deployment.
Launched 2018 Ford Fusion rear lighting. Teamed up with Mexico-based plant and customer operations to PPAP one month before customer’s SOP.
LEAD ENGINEER, BODY EXTERIOR LIGHTING. FLEX-N-GATE APD, ALLEN PARK, MICHIGAN. SEP 2015 – OCT 2016.
Served as lead engineer, holding full accountability for the development of designs and products to meet client specifications.
Directed engineering design and development initiatives for vehicle exterior lighting projects, achieving all program milestones.
Championed engineering design and development of the 2018 Ford Expedition’s headlamps, defining design and manufacturing best practices in partnership with studio and engineering management stakeholders to meet stringent deadlines.
Worked with CAD, program management, manufacturing, purchasing, and suppliers to meet all program deliverables were met.
GROTE INDUSTRIES
Madison, Indiana
AUG 1996 – SEP 2015
ENGINEERING LEAD (2013 – 2015)
Oversaw and directed five project managers, driving efforts to maximize product reliability, introducing SKUs, implementing value engineering practices, requalifying products, and rationalizing SKUs.
Drove cost saving and revenue growth initiatives to optimize results and impact profitability.
Identified value engineering opportunities by reviewing SKUs, analyzing bills of materials, and developing buckets with associated cost trends over a five-year period.
Championed the compliance expansion of current model products to broaden the scope in different markets, supporting sales team efforts leading to additional sales of $2M.
Led continuous process and performance improvement across globally based teams, employing best practices and methodologies.
Partnered with sales, engineering, and operations teams across Germany, Canada, China, and Mexico to implement principles of lean product development and solutions while improving cycle time 26% across all branch plants.
Led professional development and training programs at minimal cost by leveraging the knowledge and expertise of subject matter experts, suppliers, and the community college to effectively train and coach team members.
Drove risk management and systems compliance by serving as internal auditor for TS16949 and ISO-14001 certifications.
LEAD ENGINEER, LED FORWARD LIGHTING (2011 – 2013)
Prepared and delivered concepts, industrial designs, quotations, and technical journals to support business development and sales efforts to secure new customers determining opportunities to support business processes.
Supported business development and provided technical guidance to further the development of innovative design concepts.
Coordinated and facilitated workshops, detailing the application of next generation LED forward lighting products for Scania trucks, a European-based truck company, securing business orders of Euro 10 million.
Analyzed requirements and constraints of various applications; prepared concepts and developed functional prototypes, enabling a design freeze on next generation lighting.
ENGINEER, LEAN MANUFACTURING (2009 – 2011)
Promoted to drive process improvement through the implementation of LEAN manufacturing programs and principles, including single piece flow, TAKT time, value stream mapping, method and motion improvement, video recordings, time studies, and 5S practices and protocols per TOYOTA production system.
Supported the build of a high performing infrastructure, leading product design and development, and contributing to cost savings.
Partnered with production leadership in building a data-driven visual organization, leading efforts to identify and eliminate waste and prepare key performance indicators (KPIs).
Re-engineered products to improve process efficiencies across value chain.
Secured $2+ million in savings by directing the implementation of the future state lean manufacturing across eight work cells for various products and different customers.
LEAD ENGINEER, SIGNAL & INTERIOR LIGHTING (2006 – 2009)
Served as the lead engineer for signal and interior lighting, charged with collaboration with local fleet in field testing new LED signal lighting and an LED interior utility lamp.
Generated revenue growth, led cost savings initiatives, and oversaw the engineer of high-performing, cutting-edge products.
Streamlined manufacturing by re-engineering multiple LED signal lighting products to use a common platform, enabling broader product offerings and a subsequent 50% increase in sales revenues with improved profit margins.
Achieved recognition for performance and success, earning two patents for the design of the lens.
Captured value engineering savings of $1+ million by conducting VAVE for part count reduction.
Early Career Success: Lead Engineer, Turn Signal Switch Product Line and Project Engineer at Grote Industries and Business Development Team Lead at Minda Industries Limited (India).
EDUCATION & CREDENTIALS
Master of Business Administration (MBA) in Organizational Leadership, Marketing, & Operations Management – UNIVERSITY OF FINDLAY, Findlay, Ohio, United States.
Bachelor of Science in Tool Engineering – J.C. BOSE UNIVERSITY OF SCIENCE & TECHNOLOGY, YMCA, India.
Diploma in Tool & Die Making – DELHI INSTITUTE OF TOOL ENGINEERING, India.
Board Member Lamplighter (Grote): Championed War Veteran Causes, raised $22K to support veterans with PTSD, Robley Rex VA Medical Center at Louisville, Kentucky. Supported various other causes with Lamplighter.
Four Patents: Processed Bolt End, Turn Signal Switch Assembly #7687729; Lamp Lens Design #D630354; Lamp Mounting System #6073898; & Wrap Around Terminal for Turn Signal Switch #7119293
Citizenship: Naturalized US Citizen
REFERENCES
1.Onofrio Defina *******.******@*******.*** +1-248-***-****
a.Onofrio was the CEO of UFI Filters USA, 50 W. Big Beaver Rd., Suite 440, Troy, MI 48084.
2.Andrea Prando ******.******@**.**********.*** +1-248-***-****
a.Andrea was my supervisor (PM director Americas) at UFI Filters USA, 50 W. Big Beaver Rd., Suite 440, Troy, Michigan 48084.
3.Patrick McAleer ***********@*****.***, +1-586-***-****.
a.Patrick was my supervisor as Local Program Manager (LPM) at Marelli, 3900 Automation Ave. Auburn Hills, Michigan 48326.
4.Steve Howser *******@**********.***, +1-812-***-****
a.Steve was my supervisor (Director Engineering) at Grote Industries, 2600 Lanier Dr, Madison, Indiana 47250
KARAN DUA
***********@*****.***
Novi, Michigan 48377
busi
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