Automotive Technical Project Leader

Kaush Singh

734-***-**** *****.*****@*****.*** Canton, MI

Technical Project Leader – Automotive Interior/Exterior Vehicle Engineering Product Delivery Automotive engineering and technical project management leader with 20+ years of experience delivering vehicle systems from concept through system integration, validation, manufacturing readiness, and launch. Advanced experience in vehicle restraint and safety systems, including airbags, seat belts, steering wheels, seats, interior trim, body structures, closures, and related vehicle interfaces. Former automotive interior/exterior system launch leader for multiple Ford truck and SUV programs. Proven success managing suppliers, engineering changes, BOM development, validation testing, component procurement, program schedules, risks, dependencies, and cross-functional deliverables. Experienced leading engineering, safety, quality, manufacturing, purchasing, supply chain, logistics, and supplier teams across complex vehicle development programs, including electric, hydrogen fuel-cell, diesel, and CNG platforms.

KEY QUALIFICATIONS

Technical project management across vehicle development programs

Automotive Inferior/Exterior systems integration, design verification, validation testing, and launch

Supplier performance, development timelines, tooling, PPAP, and manufacturing readiness

Program schedules, milestones, dependencies, risks, escalation, and mitigation

BOM maturity, engineering requirements, engineering changes, and component delivery

DFMEA, PFMEA, DVP&R, control plans, functional targets, and validation plans

Test-component procurement, logistics coordination, build support, and issue resolution

Cross-functional leadership across engineering, safety, quality, manufacturing, purchasing, and supply chain

Root-cause analysis, corrective actions, change management, and continuous improvement

KPI tracking, dashboards, executive reporting, and decision support

CAD, CAE/FEA, GD&T, 3D tolerance analysis, PLM, ERP, and Gantt schedules

Design for manufacturing, design for assembly, VAVE, cost management, and product quality

Three patents related to vehicle interior functionality and ambient lighting PROFESSIONAL EXPERIENCE

SAF-Holland (Tier 1 supplier for commercial truck Air Suspension and 5th Wheels), Muskegon, MI 2025-2026 Engineering Manager – Powered Vehicles Application Engineering

Created detailed milestones, task plans, dependencies, and risk controls for six 2026 projects, improving schedule visibility and delivery discipline.

Led VAVE project initiatives representing $5.3 million in cost savings and revenue enhancement while maintaining product functionality and quality.

Led engineers and designers responsible for the design, testing, validation, and launch of safety-critical air-suspension and vehicle-coupling products for commercial and vocational trucks.

Managed multiple engineering programs simultaneously, aligning internal teams, suppliers, OEM customers, manufacturing plants, and truck fleets around schedules, milestones, testing, and launch deliverables.

Served as engineering and technical lead for Daimler Truck North America, PACCAR, Oshkosh, Volvo, and Navistar programs.

Oversaw supplier performance, design changes, validation activities, manufacturing readiness, and technical issue resolution.

Developed and implemented Product Change Request, Supplier Change Request, and Design Change Planning processes to strengthen engineering-change tracking and cross-functional execution.

Led DFMEA, DVP&R, and validation testing for safety-critical air-suspension and coupling products.

Coordinated engineering support for North American manufacturing plants, resolving design, warranty, quality, and production issues through structured root-cause analysis.

Increased engineering and CAD productivity by 25% through coaching, cross-training, workload alignment, and team reorganization

Battle Motors (OEM for Diesel/CNG/BEV Heavy Duty Class 8 Trucks), New Philadelphia, OH 2024-2025 Sr. Engineering Manager – American Cab Body Engineering

(Products: all new conventional Heavy/Medium Duty Class 6 truck for The American project)

Led vehicle development and system integration for a new Class 6 truck, with responsibility for cab body structures, closures, sealing, hardware, glass, interior and exterior trim, seats, and restraint systems.

Built and managed five engineering teams covering body and closure structures, hardware and sealing, interior trim, seats and restraints, and exterior systems.

Translated vehicle-level safety, performance, quality, cost, and timing requirements into engineering plans, program milestones, KPIs, and design-validation activities.

Managed BOM development and maturity, engineering requirements, supplier sourcing support, DFMEA, validation planning, engineering changes, technical risks, and program dependencies.

Coordinated cross-functional engineering teams and suppliers to resolve open technical questions, maintain development timelines, and prevent program delays.

Reported program status, engineering risks, dependencies, mitigation plans, and decisions directly to the Chief Technology Officer.

Led supplier engagement for component design, validation, cost, quality, manufacturability, and delivery.

Facilitated integration activities across cab structures, interior systems, seats, restraints, closures, sealing, and related vehicle interfaces.

Met or exceeded cab-body and closure CAE functional targets by 21% at the T2 milestone.

Established engineering methods for body architecture, master sections, design feasibility, competitive benchmarking, and concept assessment.

PACCAR (OEM for Diesel/CNG/BEV Heavy/Medium Duty Class 6-8 Trucks) – Kenworth division, Kirkland, WA 2022-2024 Engineering Manager – Body/Chassis CAE & Dimensional Management

(Products: T680/T880 Battery Electric Vehicle (BEV), T680 H2 Cell EV, and T880 Occupational truck)

Managed and mentored 12-14 engineers in two design disciplines: Body/Chassis Structural Computer Aided Engineering (CAE) and Outer/Inner Body Dimensional Management/Craftsmanship. One team in North American and another one in India.

Led product-development and continuous-improvement activities for battery-electric and hydrogen fuel-cell vehicles.

Managed cross-functional execution against program milestones, functional targets, KPIs, quality requirements, and engineering deliverables.

Implemented DFMEA- and DVP&R-driven FEA tracking, reducing average CAE delivery time from 6.0 days to 3.9 days.

Improved GD&T drawing-audit first-time pass rate from 59% to 86.6% through clearer metrics, coaching, and process controls.

Increased dimensional-delivery team productivity by more than 90% through reorganization, workload management, and technical coaching.

Developed and deployed a new dimensional-management process for component design delivery and validation.

Led structural durability analysis and design recommendations for body, chassis, and powertrain subsystems.

Assessed and deployed CAE/FEA methods and best practices to improve analysis accuracy, reliability, and turnaround time.

Completed 11 continuous-improvement projects in 2023–2024, generating $200,000 in savings while improving design quality and delivery efficiency.

Developed and delivered FEA, GD&T, and 3D tolerance-analysis training to more than 220 engineers. Ford Motor Company (OEM for Cars and Light/Medium Duty Trucks), Dearborn, MI 1991-2022 Team Leader – Interior/Exterior Systems Design/Craftsmanship Engineering 2009-2022

(Products: Ford F-150 Lightening, F-150, Bronco, Transit EV, Expedition, Mustang; Lincoln Continental)

Led teams of 6–8 engineers responsible for interior and exterior craftsmanship, dimensional quality, component approval, and launch readiness across more than 15 vehicle programs, including the F-150 Lightning, F-150, Bronco, Transit EV, Expedition, Mustang, and Lincoln Continental.

Directed cross-functional engineering, quality, manufacturing, and supplier teams through design development, validation, change implementation, and vehicle launch.

Delivered interior and exterior components for more than 15 successful vehicle launches, meeting or exceeding fit, function, craftsmanship, and perceived-quality targets.

Managed program issues and metrics through quality-system dashboards, escalating critical risks and reporting status and corrective actions to senior leadership.

Led pre-production vehicle audits and drove more than 200 issues per launch toward closure across engineering, manufacturing, quality, and supplier teams.

Coordinated dimensional approvals and pre- and post-grain appearance approvals for more than 1,500 interior and exterior trim parts supplied by over 120 suppliers.

Worked directly with suppliers to align dimensional, appearance, tooling, PPAP, manufacturing-readiness, and quality expectations.

Introduced the Fit-to-Nominal process and trained more than 300 engineers and suppliers on improved trim fit-and-finish delivery.

Developed and published the ES1298 tolerance specification for plastic parts, enabling repeatable fit, function, and launch-quality performance.

Reduced checking-fixture and gage costs by establishing common interior-trim gage content and locator strategies.

Maintained concise status reporting for program accomplishments, open issues, risks, and quality performance. Launch Leader/Senior Product Design Engr - Interior Trim & Restraints Engineering 1999-2009

(Products - Ford: Explorer, Expedition, Mustang, F-Series 150; Lincoln: Navigator)

Led the design, integration, verification, validation testing, manufacturing readiness, and launch of automotive restraint and safety systems, including airbags, seat belts, steering wheels, and related interior and seating interfaces.

Served as restraint-system launch leader for the Ford Explorer, F-Series, Expedition, and Lincoln Navigator vehicle development programs.

Managed restraint and interior components from concept through production, including requirements, BOM content, supplier execution, engineering changes, testing, cost, quality, manufacturing readiness, and launch.

Coordinated suppliers responsible for restraint-system design, tooling, prototypes, test components, validation, PPAP, production readiness, and launch delivery.

Worked across restraint engineering, vehicle integration, occupant packaging, body engineering, interior trim, seats, quality, manufacturing, purchasing, and suppliers.

Tracked supplier development timelines, component availability, validation status, engineering changes, risks, and dependencies to protect vehicle build and launch schedules.

Coordinated procurement and logistics for prototype and validation components supporting test and pre-production vehicle builds.

Led floor-console and soft-trim launches for Ford Escape and Mustang at multiple assembly plants.

Drove cost-reduction programs across seat belts, steering wheels, airbags, carpets, consoles, and related commodities.

Developed durability requirements and validation methods for new interior-storage systems.

Earned three patents for interior-storage and ambient-lighting features and was named a Society of Plastics Engineers award finalist.

Senior Product Design Engineer – Body Structures/Closures Engineering 1991-1999

(Products - Ford: F-Series 250, F-Series 350, Excursion)

Managed group of six to eight supplier engineers and led design/development/launch of all new Body (BIW) Structure, Front End Structure, Hood/Fenders, Front & Rear Side Door Structures, Door Glass, Glass Regulators, Hardware, Weather-strip Seals from product concept to launch phase. Proficient in Design for Assembly, Design for Manufacturing, Body Structure Optimization etc.

Led Design/Verification of Ford 1st Hydroformed Radiator Support Assembly and Front-End Sheet Metal sub-systems from concept to prototype. Reduced part complexity and cost

Led design feasibility for manufacturing and assembly of sheet metal stampings and hydroformed tubes

Launch leader for the 2000 Ford Excursion Door Systems at Kentucky Assembly Plant

Assessed/implemented the latest technologies such as Laser Welded Blanks, Hydroforming, etc. to achieve cost savings

Developed DFMEAs, PFMEAs, DVP&Rs, and Control Plans for Door and Window Hardware systems and led testing for door durability, door closing efforts, wind noise, water leak, etc.

Led Value Analysis & Value Engineering (VA&VE) activities to optimize Design/Process/Cost

Proficiency in automotive quality systems and coached suppliers on Lean/Quality production system proficiency during Manufacturing Readiness and PPAP reviews during multiple launches

Developed/Implemented upfront CAE/FEA driven Body Front End Structure Design Validation SELECTED PROGRAM IMPACT

Led restraint-system development and launch for Ford Explorer, Ranger, Expedition, and Lincoln Navigator programs.

Delivered airbags, seat belts, steering wheels, seats, interior trim, body structures, closures, chassis, and suspension components across 15+ vehicle launches.

Managed component approval and supplier execution covering more than 1,500 parts and 120 suppliers.

Generated $5.3 million in VAVE cost savings and revenue enhancement at SAF-Holland.

Reduced CAE delivery time by 35% and improved GD&T first-time pass performance from 59% to 86.6% at PACCAR.

Improved engineering productivity by 25% at SAF-Holland and dimensional-delivery productivity by more than 90% at PACCAR.

Trained more than 500 engineers and suppliers in FEA, GD&T, tolerance analysis, craftsmanship, Gage R&R, and plastic-part design.

Supported advanced vehicle development programs spanning battery-electric, hydrogen fuel-cell, diesel, CNG, light-, medium-, and heavy-duty vehicles.

TECHNICAL EXPERTISE

Restraints and Safety Systems: Airbags, seat belts, steering wheels, seats, occupant-safety interfaces, restraint-system integration, component testing, design validation, manufacturing readiness, and launch Technical Project Management: Program schedules, milestones, Gantt planning, development timelines, BOM maturity, engineering-change tracking, dependency management, risk identification, mitigation planning, issue escalation, KPI reporting, and executive reviews

Supplier and Component Management: Supplier performance, sourcing support, tooling, prototype and test components, procurement coordination, logistics, PPAP, manufacturing readiness, component delivery, root-cause analysis, and corrective actions Engineering and Validation: Requirements management, system integration, DFMEA, PFMEA, DVP&R, control plans, CAD, CAE/FEA, GD&T, 3D tolerance analysis, functional targets, durability testing, and design verification Vehicle Systems: Restraints, interiors, exteriors, seats, body structures, closures, sealing, hardware, glass, chassis, and air suspension Manufacturing: Injection-molded plastics, fabrics and soft trim, sheet-metal stamping, hydroforming, tooling, design for manufacturing, design for assembly, quality systems, and production launch Vehicle Platforms: Battery-electric, hydrogen fuel-cell, diesel, CNG, passenger cars, SUVs, light-duty trucks, commercial trucks, and vocational vehicles

EDUCATION

Doctoral Studies (Completed course-work for Ph.D.) – Mechanical Eng., North Carolina State University, Raleigh, NC Master of Science (M.S.) - Mechanical Engineering, Ohio University, Athens, Ohio Bachelor of Engineering (B.E.) – Mechanical Engineering, Indian Institute of Technology, Roorkee, India PATENTS

U.S. Patent No. 7513533 – Automotive Console Storage with Repositionable Bin, April 7, 2009

U. S. Patent No. 7237816 – Automotive Center Console with Open Front Face, July 3, 2007

U.S. Patent No. 7267385 – Vehicle Trim Locating and Attachment System, September 11, 2007

Publication No. 201******** – Occupant Interactive Accessory Sys. for Vehicle Interior, Aug. 17, 2010 TECHNICAL PUBLICATIONS

Published/Presented 15 Technical Papers at various US/international Engineering/Quality conferences/ symposiums AWARDS

SAF-Holland Eng. Director’s Award for Fasteners Resourcing VA/VE Cost Savings, 2026

Ford Chief Engineer Award for Ford Expedition Int./Ext. Trim Fit/Finish Design/Launch Lead, 2019

Ford Chief Engineer Award for Ford 1st successful implementation of Fit to Nominal process, 2014

Ford Chief Engr. Award for Plastic Tolerance Specification/Training (ES1298) Development, 2012

Finalist of Society of Plastic Engineering (SPE) Awards for Interior Ambient Lighting, 2008

Ford Body Technology Innovation Chief Engr. Award for Ford 1st Interior Ambient Lighting, 2007

Finalist of Society of Plastic Engineering (SPE) Awards for innovative design of Console, 2007

Ford Body Technology Innovation Chief Engr. Award for innovative design/lunch of Console, 2006 FORD TECHNICAL EDUCATION/CERTIFICATIONS

Six Sigma - Black Belt Robustness: Parameter Design of Experiments Finance for Engineers Project Management Systems Eng. Fundamentals DVP & PV Testing Reliability I 6σ – Green Belt APQP & PSW Design for Manufacturing Design for Serviceability Failure Mode & Effect Analysis PROFESSIONAL ASSOCIATIONS

SAF Holland Employee Involvement Committee – Active member of social & team building events planning team, 2025-2026

Recycling & Circular Design Congress – Chaired 1st day of conference, Detroit, 2024

Lightweight Materials Congress – Chaired 3rd day of conference, Detroit, 2023

Kenworth Diversity Council – Active member of Communication Enhancement subcommittee 2023

Society of Automotive Engineers (SAE) – Board member for Seattle chapter (2022-24)

Lightweight Materials Congress 2022 – Chaired 1st day of conference, Detroit, 2022

Society of Plastic Engineering (SPE) – Speaker at 2013 Automotive TPO Conference

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