Senior Project Lead Engineer at Hasbro India Development LLP (2021-04 – Present)
Led NPD program management for global consumer product lines — managing cross-functional teams across Design Engineering, Manufacturing, Quality, Supply Chain, and global US R&D stakeholders through structured stage-gate process from concept through production launch.
- Managed end-to-end project schedules, resource plans, budget tracking, and gate milestone delivery — maintaining KPI dashboards and program health reports for senior leadership review.
- Drove tooling and product RFQ management with direct supplier/vendor engagement — conducted techno-commercial evaluation, negotiated on cost and timeline, and aligned vendor deliverables with BOM cost targets.
- Led VAVE and continuous improvement programs — contributing ₹2Cr+ in cumulative savings through DFM-driven redesigns, material optimisation, and supplier rationalisation.
- Managed DFMEA, DVP, and PPAP documentation across concurrent programs — ensuring design risk identification and closure before production release.
- Implemented lessons learned and process improvement initiatives across multiple programs — standardising gate checklists and documentation practices to improve delivery efficiency and quality compliance.
- Developed and maintained a strong Tier-1 and Tier-2 supplier base — identifying, evaluating, onboarding, and qualifying suppliers to support new product development programs and ensure 3-month SOP readiness.
- Reviewed DFM (Design for Manufacturability) and Mold Flow analysis with suppliers — evaluated tooling designs, identified manufacturability risks, and released TKO (Tool Kick-Off) approval upon satisfactory review.
- Made frequent visits to Tier-1 and Tier-2 supplier facilities — witnessed actual development progress, reviewed proto builds, monitored tooling trials, and resolved technical issues on-site to maintain program milestones.
- Conducted Product and Process audits at supplier facilities for new development parts — verifying manufacturing process capability, tooling readiness, and quality control compliance before PPAP submission.
Deputy Manager – Product Development (NPD Program Management) at Minda Industries Ltd. – Switch Division (2010-08 – 2021-04)
Led end-to-end NPD program management for Switches, Sensors, Control Panels, and Electromechanical Assemblies — managing programs from RFQ receipt through concept, design development, tooling, PPAP, and SOP for major OEM accounts including TVS Motor, Hero MotoCorp, Bajaj Auto, KTM, BMW Motorrad, Honda, and Mahindra 2Wheeler.
- Reviewed and signed off TRSO (Technical Requirements Sign-Off) with suppliers — covering Bill of Materials, Customer Input Requirements, Capacity Confirmation, Scope of FTG (Fit, Test & Go), and Zero-Based Time Plan to establish a robust program foundation at initiation phase.
- Monitored and drove supplier performance across cost, quality, delivery, and continuous improvement parameters — conducting regular supplier review meetings and escalating performance gaps with corrective action plans.
- Tracked and reported project timelines, APQP stage progress, material readiness, and procurement risks for vehicle build schedules — providing program health updates to OEM program teams and internal leadership.
- Reviewed and approved PPAP documents — evaluated dimensional reports, material test certificates, capability studies (Cp/Cpk), control plans, PFMEA, and MSA results before releasing PSW (Part Submission Warrant) to suppliers.
- Managed CMF (Color, Material, Finish) approval process in coordination with OEM design studios — obtained CMF sign-off, FTR (First Time Right) confirmation, and Installation Sign-off for cockpit switch packs, handlebar assemblies, and instrument panel components.
- Implemented lessons learned and continuous improvement initiatives across multiple concurrent programs — standardised APQP documentation practices, gate review checklists, and supplier audit formats.
- Led IMCR (Integrated Materials Cost Reduction) proposals and implementation — identified cost reduction opportunities across materials, tooling, and manufacturing processes, contributing to ₹6Cr+ in cumulative VAVE savings.
- Managed CBS (Combined Braking System) program per IS-14664 — designed force-controlled link mechanism, coordinated prototype vehicle validation across OEM test tracks, and managed full regulatory documentation for homologation approval.
- Delivered 7 granted patents for novel switch and sensor mechanism designs — demonstrating sustained engineering innovation within structured NPD program governance.
