Jun 2025 – Present · 10 mos

Jan 2025 – Jun 2025 · 5 mos

• “Contributed to the early development of exterior components for the New Ranger and Everest, delivering initial milestones before transitioning to a new role.”
• Key Contributions:
• Initiated development of Liftgate Applique, Box Side Step Cover, and Tailgate Badge.
• Delivered early design feasibility, BOM setup, and requirement compliance for initial GPDS milestones.
• Partnered with suppliers and cross-functional teams to establish manufacturing feasibility and robustness pathways

Sep 2023 – Jan 2025 · 1 yr 4 mos

• Flagship Innovation: Drove Ford’s first composite foam-core running boards — a world-first innovation in automotive mass production. Achieved ~US$15M cost savings, 30% weight reduction, and delivered global launches across South Africa, South America, and Thailand within 18 months now launched on Ranger , Ranger Raptor , Ranger Superduty .
• Recognized with multiple Asia-Pacific awards from Chief Engineer and General Manager for innovation and accelerated execution.
• Key Contributions:
• Design blow-molded foamcore composite running boards(blow-molded sandwich with structural foam), never before applied in automotive products using this Technology.
• Delivered ~30% of departmental cost-reduction targets through design efficiency as part of this project. and 4.5Kg weight reduction /car
• Led full lifecycle: CAD/BOM, DFM/DFA, DFMEA, DVP&R, PPAP, launch readiness, and change management.
• Partnered with Thailand supplier ecosystem; work closely with Ford North America Core team to scale Technology & industrialization across global IMG programs in collaboration .
• Established a New Technology Application Readiness playbook for Foam Core Technology (validation gates,check points , DV/PV, durability & safety checks, patent search ) which can now be used as a repeatable Ford framework.
• Reduced design complexity by developing a commonized, plug-and-play mounting solution across truck lines for Ranger and currently being used across multiple Body Styles of Ranger.
• Keywords: Body Exterior | Running Boards | Foam-Core Composites | Blow-Molded Sandwich Structures | Structural Foam | DFMEA, DVP&R, 8D, PPAP, DFM/DFA | Supplier Industrialization (Thailand, Global) | Cost/Weight Optimization | Technology Readiness | Cross-Regional Launch | Innovation Recognition

Jan 2023 – Sep 2023 · 8 mos

• Led multi-million-dollar cost reduction initiatives in Body Exterior systems for Ford International Market Group (IMG) across different ford plants ensuring scalability and repeatability of Savings, managing projects from idea feasibility through design, validation, and production launch. Partnered with suppliers and cross-functional teams to deliver sustainable savings and drive VA/VE innovation.
• Key projects: Box Side Step blow-molding conversion (US$1M/year savings) and Bumper localisation for Vietnam ($ 0.5 mils USD/year) , various other exterior trims & ornamentaion parts (eg. Mudflaps, Covers etc.)
• Key Contributions:
• Converted Box Side Step from injection molding to blow molding, generating ~US$1M annual savings (~US$4 per vehicle) while maintaining performance and quality.
• Vietnam Front Fascia Localisation - (USD 7$ /Car; $ 0.5 Mils USD /year)
• Managed end-to-end feasibility and execution of engineering change projects, from concept identification through DFMEA, DVP, supplier validation, and production release.
• Delivered program content for Front Mudflaps (Super Duty UPV2), interim Roof Rails, Swing-in-Place Roof Rack, and RDM, ensuring on-time launch readiness.
• Directed VA/VE initiatives via supplier workshops, teardown events, competitive benchmarking, and internal consultations, unlocking new cost-down opportunities.
• Oversaw multi-million-dollar project portfolios, ensuring savings delivery against department targets under tight timelines.
• Drove engineering change management for current models, coordinating line trials, design updates, and launches.
• Built and tracked timing plans, securing on-time delivery of high-impact engineering projects.
• Collaborated with PD, Purchasing, Quality, and Cost Estimating teams, ensuring alignment on savings, feasibility, and manufacturability.
• Presented business cases and status and overal IMG TVM dashboards to Directors, Chief Engineers, and senior management, ensuring visibility and buy-in.

Nov 2021 – Jan 2023 · 1 yr 2 mos

• “Owned development and launch of Box Top Moldings and Tailgate Capping for Ranger 2022 across Thailand, South Africa, North America, and Argentina. Delivered on-time milestones, optimized designs across markets, and resolved launch issues without timing impact.”
• Key Contributions:
• Led end-to-end development of Box Top Moldings and Tailgate Capping for multiple global regions, ensuring feasibility, quality, and commonality of parts.
• Successfully supported international launches, meeting craftsmanship, durability, and robustness targets.
• Directed DVP & product validation with suppliers; managed DFMEA, DV testing, APQP, and sign-off processes.
• Collaborated with global suppliers and CFTs to ensure manufacturability (injection molding, punching tools) and system feasibility.
• Executed program design optimization across regions, achieving robustness, part commonality, and cost savings.
• Investigated root causes and delivered quick fixes, ensuring no delays to program launch.
• Implemented change management for late engineering changes, launch concerns, and ECNs; maintained BOM ownership and compliance.
• Innovated low-series moldings with roller-shutter trim combinations to eliminate water leak issues.
• Explored new technologies & competitive designs through benchmarking, teardown events, and voice-of-customer insights.
• Tracked and managed timing plans to ensure program milestones were met on schedule.

Sep 2019 – Nov 2021 · 2 yrs 2 mos

• “Owned end-to-end development of Roof Structures & Panel , Rear Ring Structure and Cab Back panel and Cowl Assembly for new India B-Car programs. Delivered cost- and weight-optimized BIW sheet metal designs, managed welding integration, and achieved on-time milestone delivery.”
• Key Contributions:
• Led development of BIW Upper Body structures (Rear Ring, Cab Back, Ring Frame, Cowl Assembly) for new vehicle programs, ensuring design feasibility and program compliance.
• Conducted extensive competitor and in-house benchmarking, applying VA/VE ideas to meet cost and weight targets and support the India commodity business plan.
• Acted as SPOC for welding integration of upper body structures, coordinating across my team and with the VOME team for DPA5/DPA1 welding checks.
• Collaborated with global suppliers and stakeholders to identify and implement cost-saving and weight-reduction opportunities.
• Partnered with Studio and Vehicle Architecture teams on master sections, fascia packaging, and spare tire integration.
• Created FMA and quality documentation (DFMEA, boundary diagrams, quality history, material utilization) with the Design Assurance team.
• Led cost estimation and RFQ package negotiations (T04), aligning supplier sourcing with business and cost objectives.
• Managed GPDS timelines, delivering all milestones on time, with escalations to higher forums where required.

Aug 2017 – Aug 2019 · 2 yrs

• “Supported development of seating structures for Mondeo and Endeavour, delivering 30% part cost savings while meeting GPDS milestones. Worked with 20+ global suppliers and cross-functional teams to ensure cost- and weight-efficient solutions.”
• Key Contributions:
• Supported end-to-end development of seat structures for Mondeo and Ford Endeavour, ensuring smooth GPDS milestone delivery.
• Delivered 30% part cost savings on Endeavour seat structures through value engineering initiatives.
• Addressed high-investment warranty issues, driving robust fixes and improving durability.
• Collaborated with 20+ global suppliers and internal production teams across regions and time zones, ensuring alignment on requirements and execution.
• Translated customer requirements into product specifications, balancing cost, weight, and performance targets.
• Created and maintained DFMEA, boundary diagrams, P-diagrams, quality history, and DVPs to support engineering robustness.
• Contributed to Asia Pacific cost-reduction targets by delivering cost- and weight-optimized seat structures for CD programs.
• Investigated and resolved/escalated project issues, ensuring no disruption to delivery schedules.

Jul 2016 – Jul 2017 · 1 yr

• “Completed Ford’s Graduate rotational program, gaining exposure to multiple product development verticals. Delivered hands-on projects in customer clinics, vehicle launch, and benchmarking while building a strong foundation in PD processes.”
• Key Contributions:
• Rotated across multiple PD departments and teams, gaining a holistic overview of Ford’s product development cycle.
• Led an EcoSport Rear AC vent customer clinic as a regional micro-project, presenting survey outcomes and feasibility analysis to management.
• Supported the EcoSport launch team during media builds, addressing real-time vehicle build issues and enabling quick corrective actions.
• Conducted extensive benchmarking studies for a new product line as part of the program management team.
• Built foundational knowledge in GPDS processes, cross-functional collaboration, and problem-solving in live vehicle programs.