Project Engineer Mechanical

Mayank Kumar Jaiswal

Design Release Engineer Project Engineer Mechanical Engineer Resident Engineer

Novi, MI +1-734-***-**** ********@*****.*** Linkedin

Professional Summary

A highly skilled Mechanical and Design Release Engineer with a 9+ years of experience & comprehensive background as Engineering Liaison, CAD Designer, Quality/Launch Support, Engineering Change Management, Creating and Managing timelines, tolerance analysis (GD&T), and end-to-end product development within the automotive sector. Proficient in DFMEA, DVP&R, PPAP, APQP, and PLM systems, with a proven track record of supporting robust design validation and quality assurance processes.

Led as on-site Project Engineer at Ford, launching Molex telematics, wiring, connector and powertrain products; successfully managed global NPD programs from concept to launch, ensuring cross-functional alignment, technical accuracy, and on-time delivery.

Extensive experience in wiring harness, interior & door trim packaging, antenna integration on sheet metal, and infotainment system design, with a strong focus on mechanical product design and release, design for manufacturability (DFM), and electrical system integration. Proven ability to drive cost and timing optimization, ensure sub-system validation, and provide comprehensive customer launch support across vehicle programs.

Strong command over project management and scheduling tools including Primavera P6, MS Project, and Teamcenter, enabling effective tracking of deliverables, engineering changes (PCN/ECM), and gauging launch readiness

Successfully managed concurrent automotive programs with budgets ranging from $3M to $20M, supporting global launches across North America, Europe, Asia, and Australia.

Skills

Design Skills: UG/NX, CAD, CATIA, SOLIDWORKS, GD&T

Technical Skills: DFMEA, SCCAF, DVP&R, ESER, DOE, AAR, Device Transmittals, PPAP, APQP, PLM

Project Management & Scheduling: Teamcenter, Vismockup, MSOffice, Primavera P6, MS Project

Core Competencies: Vehicle Packaging, PCN/ECM, 8D, Creating & Managing Timelines, Cost & Timing Optimization, Tolerance Analysis, Quality & Launch Support, Product Life Cycle Management (PLM)

Organizational Leadership

Delivered complete antenna system (shark fin, embedded glass, coax routing) for Ford global programs on time and within budget, meeting all GPDS gateway deliverables and maintaining 100% compliance with WERS timing.

Drove a 25% reduction in warranty returns on GPS and AM/FM reception issues by implementing improved coax shielding and connector design, validated through EMC/ESD testing at Ford Central Lab.

Implemented a modular antenna architecture using HFM Connectors reused across Truck and Van platforms across all regions, resulting in $250K annual cost avoidance through design reuse, streamlined sourcing, carry over tooling and surrogate validation.

Education

University of Michigan, Dearborn, MI

Master’s Degree in Mechanical Engineering (2014 – 2016)

JNTU Hyderabad, Telangana, India

Bachelor’s Degree in Mechanical Engineering (2009 – 2013)

Work Experience

Resident Design Release Engineer, Molex (Onsite at Ford Motor Company), August 2016

Key Project: Ford 5G Antenna Launch (Across Global Region)

Designed and developed Roof mount ANTENNA using NX/Solidworks for multiple sheet metal roofs, achieving seamless integration with electrical harnesses and improving overall vehicle connectivity. Performed GD&T stack-up analysis of antenna on sheet metal roof across multiple vehicle platforms to identify median chassis curvature, enabling tool design commonization & driving cost efficiency.

Designed and optimized wiring harness routing using CATIA/Teamcenter around the instrument panel and interior components to ensure efficient space utilization and compliance with packaging constraints.

Conducted comprehensive Packaging studies using vehicle environment data, evaluating fitment with surrounding elements such as Chassis (metal), Interior trim (doors & plastic), Connector type, Headliner, Roof, Wiring, Ducts & HVAC systems.

Conducted design studies, tolerance stack-ups on sub components such as Antenna housing (plastic) & Chassis (metal) to ensure sealing and electrical grounding to roof, while Aligning PCB components to meet design specifications and homologation requirements.

Assisted in project planning and estimation, developed schedules, and maintained project baselines and Gantt charts using MS Project and Primavera P6 to ensure on-time delivery of key milestones and deliverables.

Coordinated activities to accomplish prototype, pilot & production runs to mature the design of components and assemblies and meet customer needs for finished material.

Executed comprehensive risk assessments and applied findings to refine designs and reduce failure risks prior to production release. Reviewed Manufacturing 2D drawings and managed BOM in CAD including material selection and Manufacturing process (Injection molding, casting, stamping and plating).

Applied Lean Six Sigma Green Belt & DFMEA methodology to identify process inefficiencies, perform root cause analysis, suggest corrective actions and implement data-driven improvements, resulting in measurable cost savings and quality enhancements

Initiated and processed Engineering Change Notices (ECNs) within the Ford WERS system, managing supplier cost, timing, and compliance for both new releases and post-release changes.

Supported Ensured product and process compliance with IATF 16949 quality management standards by conducting audits, maintaining documentation, and implementing corrective actions to meet OEM and customer requirements

Coordinated with Tier-1 and Tier-2 suppliers to collect, review, and consolidate PPAP elements in alignment with APQP standards including dimensional reports, control plans

Liaise with offshore manufacturing teams, particularly in China, to ensure tooling readiness, cost-effective material selection, and sub-supplier compliance with OEM requirement

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