Tushar Shridhar Zambare
Pune
Summary
Dynamic Deputy General Manager with extensive experience at TATA Autocomp, excelling in plastic product design and project management. Proven track record in leading cross-functional teams to achieve innovative seating system solutions. Skilled in GD&T and tolerance stack-up, fostering strong client relationships to drive business growth and enhance product quality.
Overview
23
23
years of professional experience
Work History
Deputy General Manager
IAC-International Automotive Component
02.2024 - 05.2025
- Involve in Master section creation.
- Concept Finalization with TMETC team for Fabric laminated topper pad, dual side opening armrest, sliding cup holder & Laptop tray.
- 3D data generation for Mule build, DR1, DR2 releases
- Benchmarking for Various concept
- DFA/DMF/DFMEA/Gap plan finalization/Tolerance stackup/Material finalization workout
Deputy General Manager
TATA Autocomp System Ltd, IPD
10.2011 - 10.2023
- Handle complete product development cycle
- Concept Engineering
- Benchmarking, Styling
- Highlight salient features of each benchmark design
- Compare geometry, attachment features
- Prepare a comparative matrix of product features
- Use of A2MAC for benchmarking
- Early involvement during styling
- Concept generation support
- Concept studies of interfaces / moving parts
- Macro packaging feasibility support
- Tooling feasibility support
- Packaging Feasibility Study
- Develop Master & Proposal sections considering ergonomic/clearance/loading requirement
- Prepared Concept Surfaces & discuss with customer for Class A surface generation
- Product Engineering & Design (CAD)
- Define Gap plan
- Define locating strategy
- Define fixing methods
- Develop Engineering BOM
- Identify Materials / Fasteners / Std items
- Establish Design/Product Validation Plan (DV/PV)
- Establish Process flow
- Analyze Design for Assembly (DFA)
- Establish Design Failure Mode Analysis (DFMEA)
- Study Serviceability aspects
- CAD Engineering
- Quality check on 'Class A' data
- Split Class A data as per definition
- Generate 3D CAD data with the complete scheme (Locating, fixing, Process, selection of material, kinematics study and DMU studies) and generation of COD plan
- Design for tooling / manufacturing
- 2D drawings generation
- CAD Data management & Release control
- Section Development
- Create master sections with product definitions, visibility study and serviceability in consideration
- Interface study based on section
- Macro packaging feasibility study
- Use of benchmarking for packaging/Interface study
- Use of TGW/TGR of running project
- Assembly sequence/fixing/locating strategy
- Define assembly sequence based on environment
- Define locating & mounting strategy
- Use of benchmark data
- Material Engineering
- Mat. Characterization Support to Material for Following Activities
- Understanding the product requirements
- Identify / select material from data base
- Develop / Tune material spec to suit requirement
- Material characterization to support CAE validations
- Validation Engineering
- Identify & signed-off Physical & Digital validation requirement based on customer requirements
- Support CAE Team to workout component level CAE analysis-Modal Analysis, Static stiffness analysis, Durability analysis, vibration analysis, Thermal Analysis
- Support Customer CAE team for Vehicle level analysis
- Tooling Engineering
- Tool design/Prototype/Tooling Trials
- Hard/soft Tooling Activities
- Data Sharing with tooling team for feasibility check, Mold flow analysis from toolmaker.
- Support tooling to Identify number of gates/type of gate. Provide feedback on moldflow analysis & get signed-off from CFT/customer
- Modify data as per tooling feasibility & share with tooling for tool development activity
- Support tool development team for modifications. Monitor ECNs.
- Attending tool trials & provide engineering analysis on trials parts
- Workout Virtual/Physical grain mapping & get approval from customer to Initiate graining activity along with grainer
- Attend tool buyoff trials
- Rapid Prototyping
- Identify process for RPT- SLA/SLS/Machining/Vacuum forming
- Selection of Supplier
- RPT part Manufacturing & fitment tryout to Identify design modifications to meet Fit & Finish requirement
- Process Engineering
- Process selection / definition
- Establish process flow
- Product design support - DFA
- Concept design of fixtures / jigs for assembly
- Support facilities & process readiness
- Interaction with suppliers
- Equipment prove out (at supplier and plan)
- Process signoff
- Proto builds to support Engg and Customer requirements
- Launch Support
- Product Launch support
- Participate in E-cube fitment activity
- Craftsmanship reviews and approvals
- Fitments issue resolution by manual proto activity
- Dimensional analysis (reports) and approvals
- Appearance approval (AAR)
- Support to QA team for PPAP approvals
- New / Current model - Engineering Change Management
- Leading / managing Design and development team to meet customer requirements.
- Maintaining a close coordination with client regarding the new business for their technicalities and Feasibility
- VAVE proposals to reduce assembly cost
- Provide effective and inspirational leadership to the team in the unit through regular training, motivation and performance appraisals in order to achieve set targets.
- Establish healthy business relations with clients & external associates for securing repeat business & long-term customer loyalty and worked towards solving their queries and complaints efficiently.
Deputy Manager
Maruti Suzuki India Ltd
03.2011 - 10.2011
- Company Overview: India (OEM)
- Responsible for Front, Rear & Back Door design & development program for New Swift.
- Product Development: Supplier selection, RRFQ, Specification Meeting, supplier visit, tooling schedule, test schedule, ECN implementation, ECR raise, Drawing Checking & Releasing, Project Monitoring, Co-ordination with Cross Functional Team.
- Product Development: Mass production trial support, identifying the issues & taking countermeasures along with supplier, SQR, DQR, development of parts for Pilot.
- India (OEM)
Team Leader
Visteon Engineering Center, Pune, India
02.2006 - 03.2011
- Lead Design activities for Rear window shelf from India & coordination activity handle with Visteon France.
- Design support provided to Visteon USA till tool kickoff for WD 2010 door trim, DS 2009 Floor console & Door Trim.
- Travel multiple time to USA to establish coordination & communication with Visteon USA team.
Designer
Grupo Antolin, Pune, India
12.2004 - 01.2006
- Packaging studies of Passenger seat (40-60 seat).
- Part and assembly design of seat(i.e. Cushion foam, Back foam, Cushion frame, Back frame).
- Part and assembly drawings creation with GD & T.
- FMVSS Layout, Six sigma layout, Exploded view drawing creation.
Designer
TATA Johnson Control, Pune, India
09.2003 - 12.2004
- Designing & modelling of Cushion & Back foam for Driver, Co driver & 2nd row seat.
- Designing & modelling of side shield panel for driver & co driver seat.
- Creation of Safety, Comfort, Packaging, Environment, Fastener, Manufacturing Layout as per customer requirement.
- Packaging studies.
- Part and assembly design.
- Part and assembly drawings creation with GD & T.
- Exploded view drawing creation.
Designer
Mahindra Forging (Currently Mahindra Forging), Pune, India
06.2002 - 09.2003
- Design crankshaft, connecting rod, cam shaft, steering knuckle & various links using Unigraphics NX & Euclid 4.2 software for Various OEM TATA Motors, General Motors, Ford, Daimler Chrysler, Delphi Motors.
Education
Executive Post Graduate Diploma -
Symbiosis International University
12.2001
B.E. - Mechanical Engineering
Government college of Engineering
Jalgaon12.2001
Skills
- Plastic product design & development
- Seating system design
- Forging design
- Engineering business development
- Project management
- GD & T & Tolerance Stack-Up
- Fabric/PVC lamination
- Design Software: Catia V4/5, Euclid, Unigraphics
Team Handling - Team Size
27
Languages
- Marathi
- Hindi
- English
Summary
2, Plastic product design & development experience in Automotive Interiors, Worked for Various customers including TATA Motors, Toyota, Maruti Suzuki, GM, Fiat, Ashok Leyland, Isuzu Motors, Vinfast, PSA, Chrysler, Handled multiple FSS programs, Seating system design experience of 2 years & 4 months, Forging Design experience of 1 year & 3 months
Personal Information
- Passport Number: ZA190308
- Passport Expiry Date: 2035
- Date of Birth: 05/06/79
- Marital Status: married
Timeline
Deputy General Manager
IAC-International Automotive Component
02.2024 - 05.2025
Deputy General Manager
TATA Autocomp System Ltd, IPD
10.2011 - 10.2023
Deputy Manager
Maruti Suzuki India Ltd
03.2011 - 10.2011
Team Leader
Visteon Engineering Center, Pune, India
02.2006 - 03.2011
Designer
Grupo Antolin, Pune, India
12.2004 - 01.2006
Designer
TATA Johnson Control, Pune, India
09.2003 - 12.2004
Designer
Mahindra Forging (Currently Mahindra Forging), Pune, India
06.2002 - 09.2003
Executive Post Graduate Diploma -
Symbiosis International University
B.E. - Mechanical Engineering
Government college of Engineering
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