Feb 2023 – Sep 2024 · 1 yr 7 mos · Bengaluru · On-site

• ✅ Led ACES/PIES implementation for aftermarket brake components, enabling standardized product data, accurate fitment mapping, and improved digital catalogue and e-commerce readiness across global distribution channels.
• ✅ Integrated PLM and CAD workflows for digital product development, e-BOM management, and ACES/PIES attribute generation, collaborating with global engineering teams and suppliers to improve traceability and reduce development cycle time.
• ✅ Led end-to-end development of brake systems for ICE and EV platforms including system sizing, simulation, validation, and regional compliance while coordinating cross-functional teams across engineering, product management, and operations.
• ✅ Performed competitor benchmarking, reverse engineering, and supplier technical evaluations to identify product improvements aligned with market trends, customer usage patterns, and aftermarket opportunities.
• ✅ Supported product planning and portfolio decisions through analysis of vehicle performance data, customer requirements, and market insights while collaborating with global stakeholders to deliver customer-focused automotive solutions on schedule.

Apr 2021 – Feb 2022 · 10 mos · Chennai · Hybrid

• ✅ Led vehicle architecture assessments for global EV programs, optimizing packaging and layout while guiding cross-functional engineering teams using DMU and simulation tools to ensure seamless integration of brake, suspension, and steering systems aligned with vehicle platform requirements.
• ✅ Conducted teardown benchmarking and competitive analysis of EV and ICE brake and chassis systems, consolidating technical and market insights to support product planning, customer-oriented engineering decisions, and competitive positioning.
• ✅ Led value engineering initiatives for brake and chassis systems, optimizing component design, material selection, and manufacturability to improve cost efficiency, performance reliability, and alignment with evolving EV mobility trends.
• ✅ Collaborated with global engineering, product, and supplier teams to support vehicle program development and lifecycle planning, ensuring timely delivery, data-driven decision making, and alignment with customer expectations and market requirements.

Apr 2019 – Apr 2019 · 0 mo

• ✅ Completed an intensive onsite training program in brake system development, testing, and validation across commercial and passenger platforms, gaining hands-on experience with NVH mitigation, Disc Thickness Variation (DTV), pedal feel calibration, and system-level optimization for global safety and performance standards.
• ✅ Acquired practical expertise in ADAS braking technologies, including Autonomous Emergency Braking (AEB) and Forward Collision Warning (FCW), understanding their integration with ABS, ESP, and overall vehicle dynamics to ensure compliance with global safety regulations.
• ✅ Engaged in cross-functional, global learning covering OEM validation protocols, aftermarket component readiness (IAM/OES), and structured CRM feedback processes, building world-class skills in vehicle system performance, customer-oriented engineering, and advanced safety feature deployment.

Apr 2018 – Mar 2021 · 2 yrs 11 mos

• ✅ Led brake system R&D, validation, and vehicle dynamics optimization across commercial and passenger platforms, resolving brake judder, Disc Thickness Variation (DTV), pedal pulsation, and friction issues through structured testing and system-level improvements, improving braking efficiency by 18% and reducing NVH-related complaints by 30%.
• ✅ Developed a custom low-cost Disc Thickness Variation (DTV) measurement device, eliminating reliance on imported tools, reducing validation turnaround time by 40%, and delivering over $5M in direct cost savings.
• ✅ Designed brake system layouts and hose routing aligned with suspension and steering kinematics using Digital Mock-Up (DMU) tools for packaging validation and noise root-cause analysis, improving packaging accuracy by 25% and reducing assembly line issues by 15%.
• ✅ Collaborated with vehicle dynamics and controls teams to tune ABS and Electronic Stability Program (ESP) across varied load and road conditions, improving vehicle stability during emergency braking and achieving 100% compliance in system audits.
• ✅ Strengthened OEM engagement through structured CRM feedback loops and validation planning, reducing warranty claims by 34% and delivering cost savings while improving cross-functional coordination.

May 2016 – Apr 2018 · 1 yr 11 mos

Aug 2014 – Aug 2014 · 0 mo

• Visited SAIC- GM- Wuling and brake system suppliers (APG, Hunan Boyun, CTCS, TRW) in Aug 2014 for design & process audit to support for flawless launch of vehicle

Apr 2012 – Sep 2015 · 3 yrs 5 mos

• ✅ Led design and development of floor- and IP-mounted parking brake levers, performing GD&T stack-up analysis, releasing detailed technical drawings, conducting supplier technical reviews and audits, and ensuring APQP, PPAP, and QFD alignment. Collaborated globally to resolve field issues, addressing gaps in SOR and DVP&R, ensuring quality consistency. Reduced design iterations by 30%, improved assembly accuracy by 25%, and ensured timely e-BOM release across multiple platforms.
• ✅ Resolved critical brake jam issues using RED-X, DFSS, and Eleven Design Thinking tools, identifying root causes in hydraulic line routing and caliper clearance, and validating solutions via PLM ECN/ECR processes. Prevented production delays, enabled 100% on-time vehicle launch, and awarded “Work of Wonder” for innovative problem-solving.
• ✅ Brake system sizing and architecture development using BrakePro tools and vehicle geometry inputs, aligned with vehicle dynamics, regulatory standards, and market trends to achieve optimal braking performance, safety, reliability, and seamless integration with vehicle platform requirements.
• ✅ Led VA/VE initiatives and DFMEA for brake components including Brake Pad/Liner benchmarking, supplier collaboration, and e-BOM coordination, reduced component weight by 8%, and improved system reliability for global platforms.
• ✅ Conducted iterative brake pedal feel calibration and objective verification, fine-tuning pedal travel, effort, and BTMC response under varying loads, temperatures, and driver profiles. Enhanced braking confidence, achieving consistent pedal travel ±2 mm, pedal effort variation <10%, and improved customer satisfaction scores.
• ✅ Tuned ABS and ESP systems across varying loads and road conditions, collaborating with vehicle dynamics and controls teams for optimal stability, pedal feel, and compliance. Achieved 100% system audit compliance, improved emergency braking stability, and reduced stopping distance by up to 0.8 m on wet surfaces.

Dec 2008 – Apr 2012 · 3 yrs 4 mos

Sep 2007 – Sep 2008 · 1 yr · Gurgaon, Haryana, India

• ✅ Led the design and development of brake rotors and BTMC for 8 passenger car variants, ensuring compliance with DVP&R protocols and homologation standards. Used 3D CAD, FEA, and CAE simulations with cross-functional teams, reducing platform-specific duplication by 47%.
• ✅ Performed brake system calculations for pedal ratio, force distribution, thermal fade, and pad wear, integrating results into HIL and rig simulations to improve pedal feel and reduce trial iterations.
• ✅ Released component drawings with GD&T, conducting stack-up and tolerance analysis to ensure accurate assembly and manufacturability, minimizing NVH and misalignment issues.
• ✅ Led supplier technical reviews, audits, and process sign-offs for APQP/PPAP compliance. Ensured adherence to QFD, DFMEA, and e-BOM standards, mitigating production risks and ensuring global quality consistency.
• ✅ Executed VA/VE initiatives across brake components, optimizing design, material selection, and manufacturing processes. Achieved USD 5.4M savings, reduced component weight by 8%, and improved reliability without compromising performance.
• ✅ Conducted competitor benchmarking and brake system teardowns, capturing material, friction, thermal, and NVH data. Supported timely vehicle launches with validated systems, improved supplier collaboration, system reliability, and driver comfort, and delivered consistent pedal feel, NVH reduction, and thermal performance across platforms.

Jan 2006 – Sep 2007 · 1 yr 8 mos · Coimbatore, Tamil Nadu, India · On-site

• ✅ Led design and development of S-Cam air brake actuator/chamber mounting brackets for multi-axle commercial vehicles (49-ton World Truck, DLT, Tipper); coordinated FEA and dynamic load analysis, optimized geometry for torque transfer and packaging, applied GD&T and DFMEA, and released manufacturing drawings for brake system components.
• ✅ Conducted system-level benchmarking and specification finalization of S-Cam Air Brake systems, including load capacity analysis, friction interface assessment, and thermal dissipation studies. Developed standardized performance criteria for heavy-duty applications, enabling informed engineering decisions, component standardization, and alignment with Tata Motors’ safety and regulatory targets.
• ✅ Collaborated in cross-functional vehicle integration and packaging studies, analyzing suspension articulation, axle kinematics, and brake component spatial constraints using FEA structural simulations to ensure proper interference clearance and mounting robustness.
• ✅ Supported launch validation for multi-axle commercial vehicles, minimizing integration issues during SOP, improving first-time assembly quality, and reducing rework at the plant.

Jun 2004 – Dec 2005 · 1 yr 6 mos · Coimbatore, Tamil Nadu, India

• ✅ Supported CAD modeling and detailed design of turret head indexing mechanisms, developed for machining precision components in the Bajaj and BMW motorcycle powertrain assembly, including chain sprocket interfaces. Improved accuracy and repeatability in tool indexing, enabling high-tolerance machining for critical drivetrain parts in premium motorcycle applications.
• ✅ Contributed to the design and development of piercing dies, jigs, and fixtures for manufacturing processes involving Bajaj and BMW motorcycle chain sprocket and related powertrain components. Enabled consistent, high-precision fabrication of drivetrain elements, enhancing part quality and reducing rework in automotive production lines.