Sunil Kumar

Dynamic career that reflects rich experience & year-on-year success in Manufacturing Process Engineering; targeting challenging & strategic assignments in Automotive, Locomotive or Aerospace Industry; preferably in Bengaluru or Chennai. Accumulated over 19 years of comprehensive experience in the Digital Manufacturing Engineering domain, specializing in manufacturing process engineering across automotive, aerospace, and mechanical sectors, demonstrating a robust understanding of industry standards and practices. Currently functioning as a Lead Engineer at Ford Motor Pvt.

Ltd., managing a team of 12 engineers to facilitate project success and maintain alignment with corporate objectives throughout essential design and manufacturing phases. Cultivated extensive expertise in overseeing intricate projects, evolving through diverse roles that refined abilities in cross-functional collaboration, resource planning, and strategic problem-solving, significantly boosting operational efficiency. Played a crucial role in realizing substantial cost reductions and operational enhancements by effectively deploying a product cost management tool that optimized budgeting processes and improved financial oversight.

Demonstrate exceptional leadership abilities by nurturing a collaborative team atmosphere and providing effective mentorship to junior engineers, thereby enhancing their technical skills and project management proficiencies. Hold extensive knowledge of process optimization methodologies, facilitating the identification and application of best practices that improve productivity and minimize waste in manufacturing processes. Exhibit a comprehensive understanding of advanced manufacturing technologies, such as 3D CAD modeling and process documentation, essential for promoting efficiency and quality in engineering initiatives.

Demonstrated proficiency in advanced manufacturing technologies and methodologies, including Lean and Six Sigma principles, which have been pivotal in driving process improvements and enhancing product quality across various engineering projects. A forward thinking person with strong communication, analytical & organizational skills; well organized with a track record that demonstrates self-motivation & creativity to achieve corporate goals.

Lead Engineer at Ford Motor Pvt. Ltd. (2016-03 – Present)

• Team Management and Leadership: Leading a team of 6-10 engineers, implementing new initiatives resulting the increase in productivity.
• Configuring the EBOM and developing the MBOM. Preparing assembly process documentation using process sheets, illustrations, and 3D CAD models. Creating the manufacturing plant line station structure and allocating the assembly processes to the stations to achieve effective operator utilization through line balancing. Create the time studies for the stations and publish to the line to generate the operator instruction sheet, job element sheets, work instructions, etc
• Collaborating with cross-functional and international teams to resolve technical and operational issues. Conducting user acceptance testing, tracking and managing issues through MIMS (JIRA & E2KS), and updating the issue matrix for transparency.
• Planning resources per SOW, managing requirement changes in adherence to change management protocols, and organizing project kick-off meetings. Delivering on-time, quality outputs while driving continuous improvements and preparing performance metrics for leadership.
• Demonstrating strong negotiation, communication, and adaptability in challenging situations, effectively engaging with diverse, intercultural teams to deliver results aligned with organizational goals.
• Authoring process plans using Easy Plan (Teamcenter) while managing the development of Manufacturing BOMs (MBOM) to align with production goals.
• Overseeing creation of line structures and driving optimal station-wise resource allocation to maximize efficiency and throughput.
• Supporting the migration of legacy systems (from GSPAS to Easy Plan), conducting user acceptance testing (UAT), and managing issue tracking through Jira/E2KS to ensure smooth transitions.
• Publishing project performance metrics, monitoring progress, and escalating critical issues to leadership to maintain transparency and alignment.

Manager – Commodity Management Services at EWIE Services India Pvt. Ltd. (2008-05 – 2016-02)

Graduate Apprentice Trainee at BHEL, Bengaluru – ISG (2007-09 – 2008-04)

MBA in Marketing – ICFAI University (2016)

B.E. in Mechanical Engineering – VTU (2007)