Senthilkumar Balasundaram

Seasoned Automotive Leader with 24+ years of global experience in project, process, planning, and quality leadership across EV and ICE vehicle production, body shop operations, and complex assembly line execution. Recognized for orchestrating Green Field plant setups, designing advanced manufacturing processes, and leading cross-functional, multinational teams to consistently deliver on-time, high-quality vehicle launches. Adept at aligning production with crucial objectives, implementing lean manufacturing principles, and integrating advanced welding, automation, and assembly technologies to drive efficiency.

Highly competent in material, layout, and facility planning, process optimization, launch readiness, and supplier/vendor coordination, ensuring scalable, high-quality automotive manufacturing operations. Excellent ability to manage multimillion-dollar budgets, schedules, and cross-border operations while maintaining strict quality standards, regulatory compliance, and measurable productivity improvements. Trusted to lead multimillion-dollar projects, mentor high-performing teams, and deploy innovative production solutions, delivering industry-leading performance, safety, and quality benchmarks.

Excels in risk mitigation, facility and material planning, and process governance, ensuring timely vehicle launches, operational resilience, and sustainable manufacturing practices. Strategic thinker with high proficiency in leveraging data-driven insights, lean manufacturing principles, and supplier liaison to enhance efficiency.

Project Manager, EV New Model - Lucid Motors - Makkah, Saudi Arabia

(2025-06 - 2026-06)

• Drove full lifecycle EV projects, defining goals, budgets, and cross-functional milestones to deliver world-class production results.
• Led the Body Shop Green Field EV project, design, development, trials, and production handover, ensuring plan and launch targets.
• Spearheaded design and deployment of advanced Body Shop jigs, fixtures, and automation, ensuring efficiency in EV assembly.
• Executed lean and agile manufacturing strategies throughout new EV lines, minimizing cycle time and maximizing throughput.
• Led lifecycle from digital concept to verification release, driving trial execution, launch readiness, and production handover compliance.
• Managed engineering, supply chain, and production teams for executing EV model launches with zero operational delays.
• Introduced next-generation welding, joining, and automation methods, driving scalable EV production while ensuring safety and efficiency.
• Directed introduction of new models across multiple organizations, ensuring smooth start-up, production alignment, and readiness.
• Steered manufacturing, including assembly, machining, fabrication, and automation in high-volume automobile body shop operations.
• Leveraged CAD/NX, Teamcenter, and engineering tools to assist design, planning, and execution across multiple Body Shop projects.
• Steered pre-production trials, validated processes, and ensured EV lines meet production KPIs, readiness, and customer expectations.
• Applied QMS, EMS, OHSAS, energy management, and ISO standards to ensure compliance and enhance quality operations.
• Leveraged tools, process capability, and automated data acquisition to monitor performance, improve efficiency, and ensure accuracy.
• Started work in organizations including Nissan, Renault, Ford, and Maruti Suzuki, managing greenfield and relocation projects.
• Planned and drove Body Shop layouts, concepts, and designs, FTR analysis, and quality measures, ensuring precise deliverables.
• Oversaw product quality and timely site delivery, coordinating teams to meet all production milestones efficiently and maintain standards.
• Led diverse teams in EV body assembly and process planning, building expertise and fostering an innovation culture in the plant.

Project Process In-Charge, New Projects (Steering Member) - Marelli - Yoshimi Plant, Japan

(2024-06 - 2025-06)

• Supervised Steering Member production processes, leading design, development, trials, validations, and release for Nissan, Suzuki, and Italian projects.
• Managed digital-to-verification design releases, ensuring milestone adherence, comprehensive trial execution, and compliance with all quality gates.
• Successfully managed shop build activities including concept and thorough layouts, workflow analysis, and FTR checks, ensuring timely design delivery.
• Directed and documented design reviews using Teamcenter and NX software, aligning with project schedules, standards, and program requirements.

Project Management / Process In-Charge, New Projects - Renault Nissan Technology and Business Center India Pvt. Ltd. - India

(2012-10 - 2024-05)

• Led production processes for multiple new models, driving BIW component design, automation, trials, and product launch, achieving all QCD targets.
• Applied digital engineering to define process flows, weld balancing, and tooling specifications, ensuring JPH targets and manufacturability compliance.
• Evaluated jigs, grippers, payloads, and deployed PSI/DOE to validate feasibility, accessibility, reachability, and elevate overall production performance.
• Designed quality dashboards and improvements, increasing Corporate Work Order Coverage Ratio from 35% to 75% through structured programs.
• Led engineering teams for product design review, equipment design, layout planning, machine erection, vehicle trials, and launch execution efficiently.
• Prepared CAPEX/OPEX budgets, RFQs, RFIs, validated engineering changes digitally, and maintained tooling go-ahead with PFMEA risk mitigation.
• Worked with production, maintenance, logistics, and SCM teams to align trial builds, milestone approvals, and resolve in-house and customer issues.
• Achieved 90% body accuracy at ramp start and 94% at serial life through DFM standardization, early risk management, and PFMEA-driven measures.
• Supported cost reduction initiatives for Bought-Out Parts, Vehicle Tooling, and Design & Development while monitoring KPIs and milestone progress.
• Prepared and obtained Director approval for department WTB conditions, focusing on achieving crucial indicators and FY25 performance targets.

Production and Project Member, Body Shop - Ford India Pvt. Ltd. - India

(2010-01 - 2012-10)

• Developed and installed new fabrication lines strictly adhering to corporate standards, equipment specifications, and manufacturing process protocols.
• Augmented subprocess capacity from 15 JPH to 30 JPH and mainline capacity from 30 JPH to 40 JPH within 8 months through strategic planning.
• Devised space optimization and motion studies to improve worker ergonomics, minimize fatigue, and enhance productivity in Body Shop operations.
• Contributed to First Product Realization, DFA, and PFMEA by analyzing time, movements, and processes to optimize overall manufacturing efficiency.
• Secured over $1 million in cost savings through process standardization, optimization, supplier identification, and workflow improvements successfully.
• Elevated mainline automation ratio from 15% to 35% by introducing new robots, modifying layouts, and implementing weld balancing for efficiency.

Production and Project Member, Body Shop - Maruti Udyog Ltd - Manesar Plant, India

(2005-10 - 2010-01)

• Drove installation and commissioning of hemming machines, weld lines, robots, and coordinate measuring systems for new production projects.
• Steered Weld Engineering projects for new models and line relocations, including Versa, Maruti 800, and Gypsy, driving successful project execution.
• Led relocation of Versa, Maruti 800, and Gypsy lines, overseeing installation, commissioning, and layout alignment with line maker and facility teams.
• Pioneered Jig installation, automation, fixtures, tooling, and methods/process engineering in the Body Shop to meet production readiness goals.
• Implemented Lean Manufacturing, TPM, Kaizen, and continuous improvement initiatives, scaling process efficiency, quality, and safety consistently.
• Led new model door lines for Versa and Alto Minor, driving fixture modifications, working with the weld shop, engineering, SOP, and trial execution.
• Drove Sealer pump and robot installation, including Graco heated coil pump and Precision Flow S-Max commissioning for new project sealer systems.
• Pioneered full localization of imported consumables and CKD panels from Japan, achieving cost savings and strengthening supply chain efficiency.
• Engaged in overseeing the setup of the spare Door Shop, ensuring operational readiness and smooth integration with existing production processes.

Production Engineer, Body Shop - JBM Sungwoo Ltd - India

(2002-09 - 2005-10)

• Planned and directed weld shop production for Santro, Accent, and Getz lines, ensuring accuracy, efficiency, and strict adherence to production targets.
• Prepared jig layouts, line erection, and process planning for new model PA-i10, facilitating smooth launch readiness and manufacturing efficiency.

PGDOM - Operations Management - IGNOU (2006)

Certificate - Japanese Language - Japan-AOTS Training in Yokohama (2005)

B.E.

• Mechanical Engineering - I.F.E.T College of Engineering, Madras University

HSC - 12th Standard - Ramakrishna Vidyalaya Higher Secondary School

ASLC - 10th Standard - Sacred Heart Convent Higher Secondary School, Villupuram