Sunil Kumar

Project : G66/G74/G78 (BMW AG)

Module Parts: Bonnet/Fender and FCMS

• Led Bonnet, Fender, and crash management system development for G66/G74/G78.
• Drove early-phase concept development balancing cost, weight, performance, and quality.
• Developed master sections and STRAK surfaces aligned with homologation models and manufacturing needs.
• Achieved measurable weight and cost reductions while meeting crash/NVH/durability targets.
• Directed a team of 4 engineers, resolving packaging and manufacturing challenges.
• Collaborated with CFTs (Crash, NVH, Durability, Manufacturing, Purchase) to optimize design for series production.
• Managed gateway releases and published data using Prisma/CADPDM and SAP systems.
• Supported creation of DFM, DFA, DFMEA, and DVP documents with meta team and suppliers.
• Conducted meta team meetings to resolve packaging and manufacturing issues; tracked solutions and progress.
• Coordinated with project teams and suppliers to meet milestone targets for timely delivery.

Project : V436/V326/V441 (Volvo Cars Sweden)

Module Parts: Bonnet/Fender and Sidemember assembly

• Designed & developed Bonnet and Fender structures for Volvo BEV platforms.
• Developed master sections and styling surfaces with manufacturing and interface requirements.
• Engineered solutions balancing cost, weight, performance, and quality; applied GD&T for sheet metal.
• Improved corrosion resistance and water‑tightness by 20% through design optimization.
• Integrated CAE, stamping simulations, and assembly feedback into iterative design loops.
• Managed gateway releases and data security in Teamcenter and TCPLM.
• Coordinated agile sprints via VIRA/JIRA; managed a team of 4 engineers.
• Proficient in Volvo product development processes and tools.
• Partnered with CFTs and suppliers to deliver DFM/DFA/DFMEA/DVP documentation.

Project : Mahindra & Mahindra

Module Parts: Front structure, Front floor, Tunnel, and cross members.

• Designed & developed Underbody parts: Front structure, Front floor, Tunnel, and cross members.
• Developed master sections considering packaging, CAE, and manufacturing feasibility.
• Led VA/VE initiatives, saving ₹1.5 Cr annually through optimized reinforcement layouts.
• Delivered DFM/DFA documents ensuring manufacturability and assembly efficiency.
• Coordinated with CFTs and suppliers to resolve field, build, and integration issues.
• Integrated CAE stamping and CME assembly feedback to enhance design quality.
• Managed EBOM ECR/ECN processes, preparing DFM/DFA documents for stakeholder approval.
• Resolved FTR build and field issues through coordination with suppliers and customers.

Project : L405,X760(Jaguar Land Rover UK)

Module Parts: Front Doors, Fender and Side Sill assembly

• Designed BIW components (Front Door, Fender and Side Sill, Seat Cross Member) for Jaguar Land Rover.
• Delivered NVH‑compliant solutions while optimizing strength and durability.
• Created scaled 3D prototypes, accelerating validation by 30%.
• Managed releases via WERS & Teamcenter, ensuring compliance with JLR processes.
• Collaborated with CFTs and suppliers to prepare DFM/DFA documentation.

Project : ICV/HCV Mahindra & Mahindra

Module Parts: Front Door Outer/Inner, Reinforcements.

• Designed BIW closures (Front Door Outer/Inner, Reinforcements) for Mahindra ICV‑FURIO.
• Developed concepts with styling surfaces and master sections; resolved CAE & stamping issues.
• Conducted competitor benchmarking to support cost‑reduction initiatives.
• Collaborated with suppliers and CFTs to prepare DFM/DFA documentation.
• Supported cross‑functional integration during vehicle gateways and build phases.
• Managed Teamcenter EN releases, including EBOM updates and release documentation (ROCM, DCR, Pre-DCN Form B).