Sathish M
Chh. Sambhaji nagar
Summary
Assistant General Manager with 20 years of extensive experience in automotive manufacturing, specializing in BIW and stamping processes. Proven track record in implementing cost-control measures and enhancing craftsmanship quality, while collaborating with finance to manage budgets effectively. Demonstrated leadership in press and die maintenance delivery, team training, and capability building. Skilled in operational strategy, project management, and continuous improvement, with a focus on capacity planning and process optimisation. Career progression from craftsman to senior management roles at Ford Motor Company highlights expertise in root cause analysis and cross-functional teamwork. Committed to driving revenue growth through strategic planning and engineering excellence.
Overview
21
21
years of professional experience
Work History
Assistant General Manager
JSW MOTORS
Chatrapathi Sambaji Nagar
09.2025 - 06.2026
- Assistant General Manager for BIW, Stamping - New model program and plant implementation.
- Dies development - Simulation, process, design and prove out.
- Quality- Achieve craftsmanship quality to make better gap and flush without any surface issues
- Implemented cost-control measures, reducing overheads while maintaining quality of service.
- Collaborated with the finance department to manage budgets and control expenses.
- Coordinated with senior management to implement strategic plans for revenue growth.
Senior Manager
Tata Passenger Electric Mobility Limited (TATA MOTORS)
Ahmedabad
07.2023 - 09.2025
- Owns press and die maintenance delivery for BIW parts across operations.
- Leads team training and builds die maintenance capability to standards.
- Governs scorecards for downtime targets and scrap control for BIW parts.
- Drives new programme launches and aligns capacity planning with pallet design.
- Accounts for people safety improvement plans and training for new model dies.
- Oversees new-model die progression from feasibility to line try-out readiness.
- Steers current-model MTTR and MTBF performance using structured reporting.
- Sets preventive and predictive maintenance cadence for stamping dies programme-wide.
Directs supplier parts coordination and spares management for continuity. - Manages engineering change implementation and reverse engineering for BIW parts.
- Managed organisational resources to meet administrative and operational needs whilst adhering to budgetary guidelines and meeting quality and schedule demands.
Senior Engineer
Ford Motor Company
Chennai
07.2019 - 07.2023
- Led stamping feasibility simulations by driving AutoForm die process 3D and 2D.
Managed die design review, engineering change requests, and PD coordination.
Directed automation tooling design plus press line and scrap shedding simulations.
Engineer
Ford Motor Company
Chennai
01.2014 - 07.2019
- Installed press lines in the stamping shop.
- Prepared RFQ documentation by sourcing die and equipment inputs.
- Conducted BIW parts feasibility work, developing die processes and die plans.
- Led die design reviews, updating documentation and aligning with ECR changes.
- Conducted risk assessments to add control measures, creating healthier and safer healthier and safer environment.
- Provided technical support to troubleshoot, repair and maintain operational efficiencies in hydraulic, mechanical and electrical systems.
Team leader
Ford Motor Company
Chennai
01.2012 - 01.2014
- Prepared and updated team management scorecard records for reviews and follow-ups.
Planned production dies and monitored die cycle time on the shop floor. - Reduced downtime by tracking causes and coordinating actions with production teams.
Collaborated cross-functionally to support continuous improvement and kaizen activities. - Completed safety controls and prepared job instruction sheets for operators.
Modified latch hole design to avoid slug issues and scrap. - Reduced £0.4 million in scrap and rework costs through a design change.
Craftsman
Ford Motor Company
Chennai
01.2007 - 01.2012
- Tooling management and die maintenance to meet welding quality requirements through matching.
Try out die setups and correct draw and trim die issues.
Solve split wrinkles, burr, cam faults, scrap drops, and automation problems.
Junior Engineer
EL forge Ltd.
Chennai
01.2005 - 01.2007
- Supervise tool room maintenance corrections through structured inspections and follow-up actions.
Coordinate production control updates to align with corrected tooling requirements.
Investigate quality control problems and implement practical problem-solving fixes.
Education
B. Tech - Mechanical Engineering
SRM University
Kanchipuram, IN-TN2013
Diploma - Tool and Die making
Murugappa polytechnic college
Chennai, IN-TN2005
MBA - pursuing
SRM University
Kanchipuram, IN-TN06-2026
Skills
- Operational Strategy
- Project management
- Manufacturing Processes
- Capacity planning
- Process optimisation
- Continuous improvement
- Root cause analysis
- Budget management
- Cross-functional teamwork
- Team management
Accomplishments
- Delivered successful PSW and die sets with 12 to 15PSM B515 Eco Sport launch in 2011 at Chennai plant.
- 143 Engineering changes implemented for MCA program both in running dies and new dies.
Languages
Tamil
English
Hindi
Timeline
Assistant General Manager
JSW MOTORS
09.2025 - 06.2026
Senior Manager
Tata Passenger Electric Mobility Limited (TATA MOTORS)
07.2023 - 09.2025
Senior Engineer
Ford Motor Company
07.2019 - 07.2023
Engineer
Ford Motor Company
01.2014 - 07.2019
Team leader
Ford Motor Company
01.2012 - 01.2014
Craftsman
Ford Motor Company
01.2007 - 01.2012
Junior Engineer
EL forge Ltd.
01.2005 - 01.2007
B. Tech - Mechanical Engineering
SRM University
Diploma - Tool and Die making
Murugappa polytechnic college
MBA - pursuing
SRM University