Project Manager/Sr Design Release Engineer - GENERAL MOTORS - Warren Tech Center, MI-48093
(2023-05 - 2025-09)
Overall Project Management of second stage manufacturing operations for special updates of midsize trucks, develop project timing and cost estimates, business analysis, lead cross functional teams, Engineering release of special packages within the target cost, product launches. Resolved development, launch and production issues, meeting production targets of about 1600 vehicles/week.
- Achieved significant saving with process improvement by using the final wheels and tires from the production plant and thus avoiding the scrapping smaller tires used for moving the vehicles from Plant to 2nd stage operations.
- Lead/support execution of various part package installations during development and launch stages at second stage operations, including costing/feasibility studies and engineering releases, to support requirements and facilitate the production at the 2nd stage plant.
- Continue improvements on the various systems to resolve field/warranty issues and to align with the various upgrades in the vehicles.
Sr. Design Release Engineer - GENERAL MOTORS - Warren Tech Center, MI-48093
(2013-05 - 2023-05)
Developed the low restrictions street legal performance exhaust and air induction systems within the target cost and timing for next generation full size trucks, SUV and small car applications, from concept to launch, leading various activities from supplier evaluation, cost analysis and sourcing, design and development, CAE analysis reviews, engineering releases, prototype development, vehicle evaluations and noise pass-by certification.
- Executed the design and development of Torsion Bar front suspension including wheel envelope, various components, lower and upper control arms, Front Knuckle, Ball joints, stab bar, Front Dampers, Torsion Bar and various brackets for heavy-duty SUV from concept to launch leading various activities like supplier evaluation, cost analysis and sourcing, design and development, engineering releases, prototype development, DV and PV testing and vehicle launch.
- Revised designs in coordination with vehicle dynamics and Ride & Handling group to tune the suspension, setting ride height, reducing vehicle roll etc. in various GVWR conditions.
- Led multiple cross functional Product Development teams consisting of participants from various internal groups and suppliers, to develop the systems while meeting program targets for cost, performance and timeline.
- Interface various program teams and other cross functional teams to resolve issues during development phases and provide status updates to the senior program teams.
Sr. Project Engineer - HENDRICKSON INTERNATIONAL - Woodridge, IL USA
(2011-05 - 2013-05)
Front Axle systems for Class 8 Commercial Truck Applications. Led multiple engineering activities, project planning and coordination with plant, purchasing, validation, and other groups for the new product launch.
- Optimized Test Plan Matrix of various front axle beam configurations for class 8 trucks and achieved significant reduction in number of tests while meeting Reliability/Confidence criteria.
- Led design updates of fabricated axle beam, front knuckles, develop DFMEAs and cost-effective resolutions of engineering and manufacturing issues and updated engineering releases as needed.
Group Head - Chassis Systems Commercial Vehicles - TATA MOTORS LTD. - PUNE INDIA
(2009-12 - 2011-04)
Directed multiple teams of System Engineers for design and development of brakes, suspension, Wheels and Tires for light and heavy commercial vehicles with GVWR from 2.5 Ton to 16 Ton.
- Executed strategic planning and allocation of resources for the effective execution of projects from concept through various quality gates to launch, meeting the tight schedules and program targets for cost, weight and performance.
- Consolidated the wheels and tires from various groups under one group, that helped streamline the overall process of coordination with global and domestic suppliers, validation and certification and production launch.
- Led the design of suspension development with targets of best-in-class ride and handling characteristics for a passenger vehicle program with the support of leading vehicle engineering consultancy organization.
- Achieved substantial weight and cost reduction by leading the activity of introducing the parabolic leaf spring across various commercial vehicles with GVWR of up to 8.0 T.
- Resolved issues for brakes performance (brake pedal feel, poor braking) by retuning the brake system including developing brake lining, pedal ratio, pressure reduction valve for small commercial/passenger vehicle and meeting EEC/ECE and IS brake regulations.
- Led the resolution of warranty issues on brake overheating on city bus applications involving extensive field studies, retro fitment, coaching bus drivers.
Senior Project engineer - GENERAL MOTORS CANADA - Oshawa, ONT. Canada
Effectively managed all technical and commercial aspects of various projects for the design, development and integration of chassis systems, brakes, steering system, Alt Fuel (CNG) for SUVs and mid size VANs
- Designed and Developed CNG systems from concept through various development phases to launch for various configurations of G VAN, including passenger, Cargo and Cutaways.
- Developed system requirements/ specification, for brakes and steering, project cost estimates and led technical reviews for supplier selection and integration for chassis systems.
- Designed and developed power steering system including pump reservoir, hoses and saved major development time and cost by reusing existing steering gear with proper linkage analysis.
- Led the design, development and integration of complete brake system including under hood, underbody and interior packaging, parking brakes, analysis for brake sizing, friction lining development and supported various system level and vehicle level development activities to meet FMVSS requirements.
- Resolved the low frequency brake noise issue involving extensive NVH analysis, system level and vehicle level testing with various friction materials and coordination with suppliers and various groups in the organization.
- Led various engineering and program management activities, design reviews, develop DFMEA, DVP&R and APQP, DFA, cost and timing plans and providing status updates to program team.
- Managed Engineering releases, Change management, Piece/tooling cost, EWOs/ECRs, BOMs etc. and supported the Launch of multiple model lines with plants in Canada, USA, Mexico and South Korea.
Design Engineer - CHRYSLER CANADA - Windsor, ON
- Designed and developed V8 cylinder head for racing engines from concept design to completion involving valve train layout, tuning intake and exhaust ports with extensive usage of CATIA.
- Designed and developed Propane fuel system for Dodge Ram involving tank packaging, designing mounting brackets, changes to frame rails, cross-members, while meeting the structural and crash requirements with support from analysis Group and extensive usage of CATIA.
Deputy Manager – Chassis Engineering - TATA MOTORS LTD. - Engineering Research Center (ERC) Pune, India
Led design engineering group, planning, allocating and prioritizing work responsibilities for the design, development and integration of chassis systems (chassis frame, steering, suspension, brakes, propeller shaft, fuel tank, clutch and brake pedal assembly, exhaust) for light vehicles of up to 2.5 T GVWR
- Led the design and development of whole chassis systems for 2.5T GVWR vehicle in a significantly shortened program time and the vehicle was very well received in the market.
- Achieved significant weight reduction of 15% for the chassis frame structure involving redesigning of structural components, FEA analysis and vehicle level validation.
- Developed variable ratio RCB type steering gear box to reduce steering effort during vehicle maneuverability for parking. This involved coordination with global suppliers for selection of machinery, fixtures, gauges, testing equipment, for prototype development and final production launch.
- Developed brake system (Disc-Disc) and (Disc-Drum) combinations, for pickup truck application for domestic and EEC markets involving packaging studies, performance analysis and vehicle level testing.
- Designed and developed both front (Double wishbone and Mcpherson strut Type) and Rear suspension (leaf spring suspension) for 2.5 T GVWR Vehicles including Pickup Truck and SUV.
- Led the Homologation activities including creation of homologation documents, coordination of testing and various other activities for vehicles
