Khadke Sagar Mahavir

Scope of Work:
• Review & communicate the project updates & critical issues for resolution with SMEs.
• Reviewing of NPI deliverables (design reviews, DFMEA, DVP, PAT etc.)
• Review of deployment of standard practises & integration between other sub modules.
• Program Daily Work meeting with CFT.
• NPI deliverable tracking (PDSR).
• Engineering Issue Resolution / Status – including escalations.
• Engineering checks (EC) input & Feasibility checks (FC) feedback with styling team.
• Co-ordination to freeze final design from concept to meet PAT, Cost & Weight Targets.
• Design release timeline to meet program milestone.
• Weekly communicating with Attribute Team (Vehicle Engg/ VATS Teams)
i. Review & signoff targets.
ii. PAT test planning, analysis & status review.
iii. Development of solutions for performance failures / improvements.
• Review Project progress, resolve Integration issues, Improve quality & cost.
• Review of critical issues & prioritization of actions.
• Review of cost & timeline status at each gateway.
• CAB (Change approval board) Approvals.
• Review of cost & timeline status at each gateway.
• Feed engineering inputs for Supplier finalization.
• Review critical Part development & quality issues.
• Arrange VMT meetings and record of meetings as per VMTL effectiveness.
• Module development planning.
• Review status of part development- QCT.
• Prioritize Actions for all VMT members.
• Identify support required & Escalations.
• Resolution of QIB / CIB, resolve quality issues during NPI.
• Tracking progress of issue resolution throughout program cycle.
• Joint evaluation of products.
• Obtain & Review DFM, build issues & PFMEA feedbacks for deciding engg. actions
• Support to build & issue resolution.
• Clarify Requirements & obtain TRSO.
• Review status of part development and Change Management.
• Planning & Status for T0 / T1 trials, Build trials & validation.
• Set the project specific deliverables.
• Review progress to ensure program delivery within time, cost & required quality.

Key Responsibilities:

Project Management of the module:
• Ensure the achievement of QCT target of the modules along with VMT members and stakeholders.
• Project manager for VAVE of Exterior Trims domain for respective platforms.
Vehicle Module Development:
• Provide Engineering specifications for Concepts as developed during KO Sign-off and Module based on PMXU for the project, Vehicle Targets.
• Design & Develop the Module aggregates together with SMTEs in line with laid down design guidelines / processes.
• Update the PMXU of the module.
• Work with other Module Leads and Zone Managers for vehicle level Integration to achieve vehicle level performance.
• Ensure closure of MINT, BITS & RDMVV issues along with VMT members.
• Closure of TRSO & TMKO with Suppliers along with VMT members.
• Manage the relationship with suppliers in terms of engineering deliverables.
• Evaluate and ensure implementation of VAVE ideas.
Budget / Resource management:
• Ensure the monthly monitoring of the engineering budget at the module level.
• Confirmation of milestone delivery by suppliers for clearing WCC (Work completion certificate).
• Create IPA (in principle approval form) & PVR’s (Project variation request).

VALUE ANALYSIS & VALUE ENGINEERING: - (TATA MOTORS PRODUCT)
• Idea generation workshop.
• Interaction with Purchase, Production Engg, Technical Serviceability, Metallurgy team, CAE, Marketing, Advanced Quality and Marketing team.
• Design Verification plan for syndicated ideas for further stages.
• Feasibility checking, syndicating, validating and taking ideas ahead for release & implementation.
• Correlation between Digital & Physical validation of proposals.
• Making Glide path to achieve FY Integrated Cost Reduction target.
• To attend workshop on cost reduction in existing products & Proposal of new ideas to achieve cost target.
• To attend customer complaints and give prompt feedback to satisfy customer.

• Expert in Catia V5 along with providing Technical Training to new Joiners as per Customer Requirement
• Horizontally deployed the Design Guideline, Best practices, CAD Methodology across the platform through COE and Major contribution to MTA upcoming GET batch
• Performing leadership role by mentoring team members and new associates for smooth transition of the project
• Good technical skills and communication skills
• Responsible for complete Design and development of programme as per OEM requirement, currently working on Plastic Tailgate (Thermoplastic) & Front & Rear bumper, also looking after design & development activity for bumper and Exterior trims
• Role- Monitor design, Design approval, A surface analysis, Customer interaction, Interaction with cross Functional Heads at all levels & collaborating with Overseas Metiers & DFMEA, DFM, Supplier visit, Tool maker interaction, Tooling feasibility, Supplier management, Tool maker identification, trial planning, Trial execution, Part analysis, Geometry check, Mold defect check, Fitment trial inhouse and customer end, Customer part approval, grain mapping, Customer feedback ECN implementation, Design Task List, Quality Checks, Product 3D & 2D
• A.1 Design Activities :
• Accountable for the design of Front & Rear Bumper, Spoiler, Claddings & Plastic Tailgate
• Feasibility study and variant matrix for Exterior Trim Parts from another programme
• Creation of Master Sections, Concept Sections, To Study the Styling surface feasibility and its requirements
• To freeze the technical sign-off sheet and Interface Mapping requirements with concern CFT, to assign GD&T inputs to concern parts as per GAP and FLUSH requirements in coordination with Geometry Engineer
• To capture TCF Must and Want needs to implement the Regulatory requirements, Suppliers feedback, Lesson Learned, DFMEA, study-review, CAE-CFD input for readiness of mature data
• Participate in Design Reviews & develop design for Manufacturing Mindset
• A.2 Project Management Activities :
• Plan and schedule the scope of work identification and distribution within team to meet the project timeline
• Accountable for the project documentation, DFMEA, DVP, SDS Input with concern CFT compliance
• To confirm the engineering maturity for tool kick off based on Interface requirements, CAE, SAM in concurrence with respective CFT for release activity
• To resolve the BUILD issues, Validation Concerns, and assign PCA, NOVA-C action plan
• Closure for TCF concerns for Production intended parts and get FTR as per quality check
• Ensure & contribute design guideline, Lesson Learned, SCMM, CAD quality checklist through COE-Trims
• Hours Estimation in response to RFQ & Support to Project Acquisition
• Manage change of scope of Work, Perimeter changes approval
• Responsible for Cost to Non-Quality (CNQ) related to CAD activities
• A.3 Development Activities :
• Supplier Interaction for related parts to meet the quality requirements and Build objectives as per design inputs
• Tooling feasibility study, supplier input, GAP and Flush checking in line with PIST and gauge Sign-Off, Inspection of part for molding defects and submit them to CMF/Styling team for Texture sign-off
• DVP testing finalization, scheduling, sign-off and tracking
• A.4 People Management :
• CAD team Management w.r.t to Performance & Development
• Identifying Learning & development Needs, Mentoring
• Ensuring Team Competence alignment to project Requirements
• Support to Induction & development of new Team Members & trainings them accordingly
• Assess skill level of Team & purpose plans to bridge Gaps
• Project 1, M&M – THAR (DL+ EPM, M & M
• Project 2: M & M – Z101, DL+EPM)
• Customer, M & M
• Project 3: Porsche Panamera G3 SDP
• Customer: Porsche
• Project 4: Ford- Lincoln CDX747-Tailgate
• Customer: Ford
• Project 5: VW–313-Trinity-Tailgate
• Customer: VW

• JLR X393
• Customer: Jaguar & Land rover (JLR)
• Scope of Work
• Lead the team & resolve complex packaging issues in BEV and ICE vehicles
• Scope involved design and packaging of the trims, maintaining necessary clearances from engine dynamics, securing cold and hot zones in front end
• Package and check for the serviceability of different components
• Coordination with Overseas design leader to understand the requirements & Co-ordinating with Teams to deliver projects
• Design reviews with technical experts & customer

• Project 1: BMW – G06 Rear Bumper Assy (Onsite at Munich Germany.)
• Customer: Plastic Omnium
• Project 2: JLR – L560 Rear Bumper Assy
• Customer: Plastic Omnium
• Project 3: Renault BFB MEGANE / BFB GT Front Bumper Assy
• Customer: Plastic Omnium
• Project 4: Renault KFB Bumper
• Design of Rear Bumper & Spoiler Assembly
• Customer: Plastic Omnium
• Project 5: PSA – P87
• Design of Front Bumper Assembly
• Customer: Plastic Omnium
• Project 6: For TOYOTA Front & Rear Bumper parts (Accessories)
• Customer, (onsite at Detroit, USA.)
• Scope of Work
• Design of Front Bumper assembly components such as Bumper skin, Upper/Lower grills, fog lamp, chrome Blades & reinforcement Parts
• Product development from given inputs (style, surrounding parts, sections, etc.)
• Coordination with design leader to understand the requirements & Co-ordinating with Teams to deliver projects following PO Standards with good quality to customer
• Studying Assembly feasibility, tooling feasibility, CAE analysis & mould flow analysis and implementing the changes in the design
• Making various proposals & concepts for fixing of bumper plastic parts considering assembly feasibility, core/cavity concepts considering different slider & lifter motions
• Generating bill of materials, Maintaining & Releasing parts & assemblies
• Development of master section & providing Proposals to customer
• Design reviews with technical experts & customer
• Feasibility (manufacturing and assembly, style) analysis
• Responsible for the quality delivery of data to customer
• Responsible for the team activities and day today records
• DATA management (Catia Enovia)
• Played Major role in setting & Development of Plastic Omnium ODC
• Responsible for Core Technical Training to New Joiners as per Customer Standards.

• Scope of Work
• Benchmarking of different cars for generating various concepts
• Concept designing for plastic components w.r.t
• Their assembly using CAS
• 3D parametric modelling of plastic components using CAS & 3D sections at different positions
• Studying Assembly feasibility, tooling feasibility, CAE analysis & mould flow analysis and implementing the changes in the design
• Making various proposals & concepts for fixing of bumper plastic parts considering assembly feasibility, core/cavity concepts considering different slider & lifter motions
• Development of plastic components including tooling feasibility studies, and 2D mfg
• Drawings creation with GD&T
• Project: - X0 Platform (Tata Tiago)
• Front & Rear Bumper assembly.