SURESH M P
DFX and Product Cost Engineer (Semiconductor Products)
Bengaluru
Summary
Results-driven professional with over 21 years of experience in production planning and control, new product development, and engineering operations. Expertise encompasses the automotive, aerospace, and electronics sectors, serving as the principal point of contact for production operations while leading strategic planning, capacity management, and quality assurance initiatives. A proven track record in streamlining material management and optimizing resource utilization through innovative techniques demonstrates a steadfast commitment to safety and productivity. Strong leadership abilities foster collaboration among diverse teams, successfully motivating over 200 members to achieve excellence in project execution and financial performance while delivering value through effective cost engineering and budget management.
Cost engineering professional with strong analytical skills and knack for optimizing project costs. Demonstrated ability to collaborate with teams and adapt to project needs, ensuring timely and budget-conscious results. Skilled in cost estimation, budget management, and financial analysis, with focus on delivering value and efficiency. Dependable, flexible, and results-driven, ready to contribute to organizational success.
Overview
21
21
years of professional experience
5
5
Languages
Work History
DFX and Product Cost Engineer
Applied Materials
02.2022 - Current
- Developed cost estimates and budgets for engineering projects.
- Analyzed project costs and identified cost-saving opportunities.
- Collaborated with project managers to ensure budget adherence.
- Conducted risk assessments to evaluate financial impacts of project changes.
- Prepared detailed reports on cost performance and variances.
- Implemented cost control measures to enhance project profitability.
- Reviewed design changes with architects and engineers to understand their impact on overall project costs before implementation.
- Collaborated with multidisciplinary teams to drive continuous improvement in cost management practices.
- Analyzed historical data to develop accurate labor productivity rates, ensuring resource estimates were well-founded and reliable.
- Enhanced profitability by identifying opportunities for value engineering and recommending cost-effective solutions.
- Created user-friendly tools for tracking project progress against established baselines, allowing stakeholders to easily monitor costs and make informed decisions accordingly.
- Conducted post-project reviews to identify lessons learned and areas of improvement in cost engineering practices for future projects.
- Assessed contract documents to mitigate financial risks and ensure compliance with contractual terms.
- Developed a standardized process for evaluating vendor proposals based on price, quality, service levels, past performance history.
- Developed comprehensive cost reports to provide management with accurate financial insights for decisionmaking.
- Established strong relationships with vendors, negotiating competitive prices without compromising quality or delivery schedules.
- Established bulk costing automation for various commodities, such as machining, sheet metal, and gas line fabrication.
- AI Costing - Leveraging AI technology for costing a variety of parts in less cycle time by using PDF drawings.
Head - Operations & PPC (Aerospace Product Group)
INDO - MIM Pvt. Ltd.
01.2013 - 02.2022
- Spearheading complete production operations, including daily production review, production planning and control, daily OEE calculation, product costing and estimation for precision components, programming on CNC Milling Manual, MasterCAM, and DelCam (Powermill), and assembling Heli-coils into components by implementing assembly methods.
- Administering the development of automotive, aerospace, engineering, and electronics components.
- Directing complete supplier management and development activities, resolving suppliers’ issues for smooth production operations.
- Ensuring the achievement and maintenance of quality targets (client’s and organizational) OTD on individual accounts.
- Driving the pilot batch to manage end-to-end functions for prototype development, as well as administering PPAP from RFQ to the approval stage.
- Managing product costing and estimation for all types of precision components.
- Releasing the prototype to customers and assessing their feedback for necessary changes in the products.
- Conducting a feasibility study before quotation, technical specification review with CFT and QA, GD&T interpretation in customer drawings, and updating the same in the process documents, as well as a process capability study and gauge R&R.
- Preparing PFD, FMEA, Control Plan, APQP, and other PPAP documents; coordinating with CFT for PPAP.
- Designing and developing tools, tool layout, and jigs and fixtures for new components.
- Analyzing FMEA results to define special characteristics for the product and processes.
- Preparing programs and setting instructions on VMC, HMC.
- Coordinating with customers to: map their requirements, analyze materials, and finalize suppliers; review product test results and documentation; check the feasibility of projects and prepare a technical agreement; resolve their issues using 8D methodology.
- Tracking the closure of open issues, coordinating with the Quality Team for Corrective and Preventative Action (CAPA), and managing the success internal run rate before customer PPAP.
- Formulating inspection/gauge plans for the components and assuring excellent quality and productivity in coordination with the CFT.
- Generating and implementing various improvement methodologies, such as Kaizen Ideas, RCA of Problems, 7QC, 8D, 5S, and PPAP.
- Approving the design of the gauge and defining the checkpoints for the drawing of the ECR with respect to quality requirements, and reviewing the feasibility study accordingly.
- Mapping competency and providing training to team members.
- Executing internal audits to assess the status of system deployment and taking corrective measures to achieve organizational objectives.
- Verifying the inspection report as a part of the pre-dispatch inspection.
- Reducing production costs by optimizing processes and tools, and improving the OEE of the plant.
- Automating various processes and procedures to improve quality and efficiency.
- Adhering to quality standards using various tools and techniques, such as PPAP, FMEA, Pareto Analysis, Quality Control Circle Activity, Six Sigma, Poke Yoke, Kaizen, and other quality aspects.
- Creating work instructions by conducting a Time and Motion Study.
- Negotiating supplier quotes with a focus on cost savings; preparing the most feasible quotation.
- Sourcing and procuring mechanical parts and components through strategic supplier selection after their performance analysis.
- Supervising tool room activities for jigs and fixtures, and press tools; conducting jigs and fixtures, and press tools trials.
- Using CATIA V5 R20 (Basic), MasterCAM, and AutoCAD to design and develop products.
- Leading and mentoring a team of over 100 members, and providing support to them to improve operational effectiveness and efficiency.
- Growth Path: Jan 2013 - Nov 2017, Group Leader (New Product Development & Production). Since Nov 2017, Head of Operations and PPC (Aerospace Product Group).
- Self-motivated, with a strong sense of personal responsibility.
- Excellent communication skills, both verbal and written.
- Proven ability to learn quickly and adapt to new situations.
- Skilled at working independently and collaboratively in a team environment.
CNC CAM Programmer & Production and Development Head
ACE INOTEC Pvt. Ltd.
03.2007 - 12.2012
- Developed and optimized CAM programs for CNC machines, enhancing precision and efficiency.
- Collaborated with engineering teams to integrate design specifications into programming workflows.
- Conducted thorough quality checks to ensure adherence to production standards and specifications.
- Mentored junior programmers on best practices in CAM software and machine operations.
- Managed over 50 headcounts and 10 or more machines.
CNC Operator / Setter (Machine Shop)
Kumar Engineering Enterprises Pvt. Ltd.
06.2004 - 02.2007
- Operated CNC machines to produce precision components according to specifications.
- Trained new operators on CNC programming and safety protocols to enhance team efficiency.
Education
B.Tech. - Mechanical
Karnataka State Open University
Bengaluru, India01-2014
Diploma - Mechanical Engineering
Govt. Polytechnic College
Tamil Nadu01.2004
Skills
Cost variance analysis
Accomplishments
- Developed 100+ Components for Woodward Actuators & Motion Controller Housings, PWA Engine Parts, Halliburton Oil & Gas & Landing Gear Parts for CESA within 36 months with Indo-Mim Aerospace
- Established Heli-coil Assembly Project to supply the assembled goods to customer
- Established Bulk Costing Automation for Quick Turnaround time
IT SKILLS
- MS Office - Word, PowerPoint, Excel and Outlook
- AutoCAD, Master Cam & Delcam
- Apriori, Siemens Teamcenter
- DFMPro (UG-NX)
- AI- MS Copilot
Key Clients
- Indo-Mim
- Pratt & Whitney America
- Woodward
- Eaton
- Moog
- GE
- HAL
- Halliburton
- Meggit
- Defsys
- Sasmos
- Triumph
- Alpha Design Pvt. Ltd.
- Alligator Designs
- Digital Juice Pvt. Ltd.
- BEL
- Veer-O-Metals
- Wipro
- Axis Aerospace
- Thales
- Titan
- AMS
- Ace Designers
- Weir Minerals
Industry Preferences
- Aerospace
- Medical
- Manufacturing
- Semiconductor
Qualitative Tools
- Audits
- Brain Storming
- PPAP
- 7 QC tools
- FMEA
- Capability Analysis
- Gauge Repeatability and Reproducibility
- Pareto Analysis
- Statistical Process Control
- Control plans
- Process Mapping
Instruments And Machine Purview
- All Conventional Machines
- CNC Milling Centers
- VMC
- HMC
Timeline
DFX and Product Cost Engineer
Applied Materials
02.2022 - Current
Head - Operations & PPC (Aerospace Product Group)
INDO - MIM Pvt. Ltd.
01.2013 - 02.2022
CNC CAM Programmer & Production and Development Head
ACE INOTEC Pvt. Ltd.
03.2007 - 12.2012
CNC Operator / Setter (Machine Shop)
Kumar Engineering Enterprises Pvt. Ltd.
06.2004 - 02.2007
Diploma - Mechanical Engineering
Govt. Polytechnic College
B.Tech. - Mechanical
Karnataka State Open University