Shambhu Mallapur

• Current Project: MY26 R4 4EVER & RS ECHO - Ongoing
• Previous Projects: Renault MY2026 HBC EV (Kiger) and MY26 RBC Triber
• Established end‑to‑end development, validation and industrialisation of automotive seating systems from concept to production
• Ensured compliance with OEM design systems and safety/regulatory standards, covering comfort, ergonomics, durability and environment
• Drove QCD (Quality, Cost, Delivery) targets across new and carry‑over seating developments
• Performed cross‑functional collaboration with Industrial Design, Ergonomics, Vehicle Architecture, Safety, Validation and Manufacturing teams
• Managed key program deliverables including timelines, BOM, technical documentation, validation plans and specifications
• Established supplier development and convergence to ensure design maturity, industrial feasibility and part readiness
• Performed close coordination with VES (Vehicle Evaluation / Inspection Team) to identify quality concerns and ensure priority closure during industrialisation
• Increased cost efficiency through design convergence, material/process improvements and carry‑over strategies
• Performed design reviews and risk assessments to ensure milestone achievement and timely issue resolution

Project: MY23 FORD Mustang_1R & 2R

• Led and managed offshore design teams to deliver high-quality engineering solutions for North American automotive programs.
• Oversaw complete seat system development, Coordinated with sub component groups like: trim, structure, handles, cables, heating, harness, and assembly components.
• Conducted seat packaging studies to ensure compliance with legal regulations and OEM standards.
• Managed program timelines, ensuring adherence to project milestones and first-time-right design approvals.
• Coordinated cross-functional design reviews with support groups to address design feasibility and quality requirements.
• Implemented product development processes aligned with Adient PLUS and OEM-specific standards to ensure timely project delivery.

Project: MY18 C1YX 2 Row Chevy Traverse and Buick Enclave and MY14 A1BL 2 Row Cadillac CTS

• Led offshore engineering teams in the design and development of complete automotive seating systems for GM programs
• Delivered seats from Phase‑0 to SOP, including product launch and engineering change management, under stringent timelines
• 5 years of oversees experience at Johnson Controls locations in USA Plymouth for Complete Seat development and launch
• Successfully launched seating systems for MY2014 Cadillac Coupe & Sedan and MY2018 Chevy Traverse & Buick Enclave
• Ensured compliance with FMVSS and ECE regulations, covering seating safety, comfort, packaging, durability and environment
• Applied strong understanding of PLUS and JIT assembly line principles during development and launch
• Led design reviews, engineering sign‑offs, and coordination with SMTEs
• Managed integration of foam, trim, metal and plastic components, ensuring safety, craftsmanship and quality targets
• Coordinated seat build, validation and testing activities to meet program milestones
• Supported plant launch and production seat build activities in Lansing, Michigan

• Project: GM Cabrio, GM D2XX
• Supported the design and development of seating systems for GM Cabrio and GM D2XX programs
• Designed and developed sheet metal components, press tools, jigs, and fixtures for automotive applications.
• Created detailed 2D and 3D models, assemblies, and technical drawings using NX and AutoCAD
• Conducted design reviews to ensure compliance with project specifications and manufacturing feasibility
• Collaborated with cross-functional teams to address design challenges and implement engineering changes
• Assisted in the validation and improvement of tooling designs to enhance production efficiency and product quality

• Tata Motors Projects:
• Designed press tools and sheet‑metal components using NX and AutoCAD
• Developed jigs and fixtures for welding, inspection and assembly
• Performed solid and surface modelling, detailing with parametric relationships
• Created die drawings as per complete process flow from blank development to qualifying fixtures
• Coordinated daily with tool room and manufacturing teams
• Supported tool try‑out, inspection and design modifications to ensure manufacturability
• Executed reverse engineering and 2D to 3D data conversion

• Coordinated closely with Design, Tool Room, Machining, CNC, Quality and Press Shop teams
• Interpreted and explained die and press tool drawings to shop‑floor personnel
• Prepared hand sketches and drawings for material cutting and tool modifications
• Planned machining and assembly of die components in line with project timelines
• Supported tool try‑outs, inspections and design modifications to ensure manufacturability
• Inspected pressed components in collaboration with Quality team
• Evaluated design changes and ensured effective implementation in tooling and production