Vrushali Lokhande
Pune
Summary
Manufacturing Engineer with 8+ years of experience in NPI, Product Industrialization, DfMA, process validation, tooling development, and global cross-functional collaboration. • Proven expertise in PFMEA/ PFD creation, routing, layout development, lean implementation, and driving efficient design-to production transitions. • New Process Development, Process Modification & Control, Facility, Toolingʼs & gauges Development. • Prepare process documents like Process flow diagram (PFD), Process Failure Mode Effect Analysis (PFMEA), Process Parameter Sheet (PPS), SOP preparation. • Cycle time study, Method study, line balancing, Poka- yoke implementation, Kaizen, 5S. • Lean Manufacturing, Process & Productivity improvement projects, Cost reduction Activities.
Overview
8
8
years of professional experience
Work History
Senior Engineer (Process planner)
Mercedes Benz Research and Development India
Pune
01.2023 - Current
- Assembly planning for VAN.EA
- Assembly process planning
- Simulation of the components for feasibility study
- EHPV calculation for parts
- Ergonomics simulation & study for the parts
- Plan and define vehicle assembly processes for Cockpit, Console and electrical modules, ensuring alignment with product design and manufacturing requirements.
- Evaluated designs from an assembly and manufacturing standpoint, identifying early risks related to feasibility, ergonomics, tool accessibility, and process robustness.
- Performed assembly feasibility studies for project vehicles, including process definition, assembly sequencing, and assembly line efficiency analysis.
- Executed eHPV time calculations using MTM-C (Mercedes-specific standards), applying MTM certification to optimize cycle time, manpower planning, and line balancing.
- Conducted ergonomic assessments, tool accessibility studies, and operator safety evaluations to ensure safe, efficient, and operator-friendly assembly operations.
- Performed digital assembly and equipment simulations using Vis-mockup to assess reachability, validate assembly sequences, and ensure tooling feasibility.
- Define, evaluate, and validate assembly tool concepts, including nut runners, ensuring compatibility with product design and shop-floor constraints.
- Prepared and reviewed AVOs in Proplan including process definition, assembly sequencing, and assembly line efficiency analysis.
- Collaborate with global cross-functional teams across Germany, Spain, integrating technical inputs, design feedback, and process improvements.
Sr. Engineer Program Manufacturing Leader (PML)
Forvia (earlier Faurecia) India Pvt. Ltd.
Pune
07.2021 - Current
- Projects Handling: 1) Stellantis PSA – PHEV E3232i (CBU Bavans)
- Stellantis PSA – MHEV E3178G (CBU Bavans)
- Stellantis PSA – CMP VAVE & HE (CBU Bavans)
- Product interface (manufacturability)
- Ensure design to manufacturing through concurrent engineering activities with product engineers.
- Ensure manufacturing feasibility
- Production System Development
- Study & develop in detail, validate, release and set-up the complete Production System of the program: equipment and tool interfaces, layout, process flow charts, material, and information flow diagram in accordance with the Group standards and program objectives
- Prepare Make or buy: - Prepare the "make" input of the MOB matrix for all remaining components (including subcontracting) - Evaluate at plant locations subcontracting possibilities
- Ensure achievement of Process, Equipment and Facility FMEA.
- Manage budget (Capex, PPA, Cash) for complete project.
- Production launch
- Coordinate with program core team & global plants. Supervise activities globally with the assistance of the PPTL(s).
- Manage the Production Part Approval Process (including Mass Production Trial and Extended Mass Production Trial).
- Manage the production launch & Support the Production Ramp-up.
Engineer in Manufacturing Engineering Department
Tenneco Automotive India Pvt. Ltd.
Pune
11.2018 - Current
- Projects Handled: 1) FML (Force Motors Limited) 2.6L BS6.
- SML (Swaraj Mazda Limited) ISUZU 3.5L BS6
- AL (Ashok Leyland) CNG
- Manufacturing Concept Design-
- Design & develop manufacturing process for new product as per drawings.
- Takt Time, Cycle time and lead time calculation.
- Design & develop process flow for product & Prepare Process Flow Diagram (PFD).
- Analysis of Make v/s Buy of child parts.
- Prepare Manufacturing bill of material (MBOM) & Routings.
- Facility, Tooling & Gauges (FTG) Readiness & Process Validation-
- Develop concept for design of Fixture, tooling, gauges.
- Prepare RFQ (Request for quotation) for fixture & tooling.
- Compare quotations from different suppliers, negotiate for price, & Finalized supplier after analysis.
- Purchase & installation of new special purpose machines.
- Do the DAP (Design Approval Process) for FTG to release it for manufacturing.
- Validation & prove out of fixtures at supplier end.
- Fixture, tooling proves out & process validation at shop floor.
- Do PFMEA & make Poka-Yoke for avoiding defects.
- Productivity Improvement & Cycle time reduction
- Improve productivity by Man, Motion, Method Study, cycle time analysis.
- Do the line balancing by finding out bottleneck operations & reduction in cycle time.
- Improve the productivity by Lean Manufacturing.
- Implementation of 5S, Kaizen, process improvement activities at workplace.
- Customer PPAP (Part Production Approval Process) & Project launching
- Conduct internal Production Trial Run to find out scope for process improvement.
- Prepare documents for customer PPAP- PFD, PFMEA, Capacity analysis sheet, Process Parameter Sheet (PPS), FTG list, Setup verification matrix, In process inspection report, Poka-Yoke verification check sheet, etc.
GET in Industrial Engineering Department
Lear Automotive India Pvt. Ltd.
Pune
11.2017 - 11.2018
- Preparing and maintaining detailed layouts of plant in AutoCAD.
- Developing and maintaining process documentations including PFC, PFMEA & HEP
- Cycle time study and Line Balancing Project along with maintaining PCN (Process Change Note)
- Study BOM of Project & Preparation of Line side storage calculation matrix for the project.
- Preparation of work balance sheet for the project as per takt time of line.
- Procure tools and equipment for recommended manufacturing methods.
- Preparation of RFQ as per product requirement & confer with vendors to determine product specification and arrange for purchase of machinery and equipment according to Specification and Quality standards.
- Productivity improvement, cost reduction and corrective actions on customer complaints through implementation of Poka-yoke and Kaizens.
Education
PGDBM - Operation Management
NMIMS Global Access - School For Continuing Education
Bachelor of Engineering - Mechanical
AISSMS College of Engineering
Pune, India01-2017
High School Certificate Exam -
M.H. High School and Junior College
Thane, Maharashtra, India01-2013
Secondary School Certificate Exam -
New English School
Thane, Maharashtra, India01-2011
Skills
- Assembly process planning
- Design Evaluation and simulation
- Line balancing and cycle time study
- Manufacturing concept design
- FTG readiness
- PFC and PFMEA
- Ergonomics evaluation
- MTM application
- ECN and PCN implementation
- Process flow development
- Cycle time analysis
- Project management
Hobbies and Interests
- Reading
- Gardening
- Dancing
Personal Information
- Date of Birth: 07/26/95
- Marital Status: Married
Languages
- Hindi
- Marathi
- English
- German(limited Proficiency)
Timeline
Senior Engineer (Process planner)
Mercedes Benz Research and Development India
01.2023 - Current
Sr. Engineer Program Manufacturing Leader (PML)
Forvia (earlier Faurecia) India Pvt. Ltd.
07.2021 - Current
Engineer in Manufacturing Engineering Department
Tenneco Automotive India Pvt. Ltd.
11.2018 - Current
GET in Industrial Engineering Department
Lear Automotive India Pvt. Ltd.
11.2017 - 11.2018
PGDBM - Operation Management
NMIMS Global Access - School For Continuing Education
Bachelor of Engineering - Mechanical
AISSMS College of Engineering
High School Certificate Exam -
M.H. High School and Junior College
Secondary School Certificate Exam -
New English School