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Ajay Sonar Email & Phone Number

Engineering Manager, Product Safety at Adient
Location: Northville, Michigan, United States 9 work roles 2 schools
1 work email found @adient.com LinkedIn matched
✓ Verified July 2026 4 data sources Profile completeness 86%

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Current company
Adient
Role
Engineering Manager, Product Safety
Location
Northville, Michigan, United States
Company size
16166 employees

Who is Ajay Sonar? Overview

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Ajay Sonar is listed as Engineering Manager, Product Safety at Adient, a with 16166 employees, based in Northville, Michigan, United States. AeroLeads shows a work email signal at adient.com and a matched LinkedIn profile for Ajay Sonar.

Ajay Sonar previously worked as Lead Engineer / Matrix Engineer at Johnson Controls and Lead Process Engineer / Project Manager at Johnson Controls. Ajay Sonar holds Master Of Business Administration (Mba), Program Management And Finance from Lawrence Technological University.

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Email format at Adient

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{first}.{last}@adient.com
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Profile bio

About Ajay Sonar

I am a driven engineering and operations professional with extensive experience in the automotive and aerospace industry.Over the years I have Design and developed various automotive components and systems. That include Instrument Panels, floor console, Pillar trim, Bumpers, Seat systems, Metal frames and Mechanism, BIW structure and fuel tank.I have In-depth knowledge of the entire product development process, including requirements development, validation, and product manufacturing and launch. I also hold two U.S. patent.I have expertise developing and utilizing all quality chain documents, DFMEA, PFMEA, Process, Flow, Controls plan. Knowledgeable about operation documents ODS, EIS, Poke Yoke check sheet.Led the Product Safety office for North and south America region. Worked with legal team on recall activities as well as government regulation.Facilitated Product Safety Manufacturing Certification (PSMC) process for 50 plus programs with multiple OEMs. PSMC was a cross functional verification process of safety critical characteristic from drawing, manufacturing document to the actual controls on the equipment.I led 100 plus Potential product safety concern investigation teams thru the complete process of identifying and establishing containment method, communication decision to all stakeholders including customer, Root Cause analysis and Permanent Corrective Action implementation and documenting all the details.I have trained and coached 100 plus program manager, Product Engineer, Manufacturing Engineer and Quality Engineers across the organization on product Safety methodology.I also worked as a Project Manager and executed multiple project to improve the efficiency and cost saving.I did work as a Cost Engineer and developed the cost database and used Design for Cost methodology to manage the cost of the components during the development phase. Worked with customer on change cost territory discussion.As a part of engineering operation I worked with and led various global teams with members from Europe, Asia, China and South America.Expertise includes:• Seat System Design & Development• CAD tools• Operations / Launch Readiness• Engineering Budget• Product Safety Management• Quality Chain Documentation• Process Improvements & Initiatives• Cost Management / Design for Cost• Project Management• BOS Audit / JIT product safety audit

Current workplace

Ajay Sonar's current company

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Adient
Adient
Engineering Manager, Product Safety
Northville, MI, US
Website
adient.com
Employees
16166
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9 roles

Ajay Sonar work experience

A career timeline built from the work history available for this profile.

Engineering Manager, Product Safety

Adient

Northville, Mi, Us

Role listed

Adient

Northville, Mi, Us

Engineering Manager, Product Safety

Adient

Plymouth, Michigan, Us

Led Product Safety office for North and south America region. Audited program during the development cycle to make sure programs meets all regulatory and customer requirements. Safety Critical characteristics are identified throughout the quality chain document. Responsible for leading Potential Product Safety investigations. Facilitated Product Safety Manufacturing Certification. Led the lesson learned process for the Product Safety investigation closed for systemic root cause analysis. Trained all stakeholders.

Lead Engineer / Matrix Engineer

Johnson Controls

Cork, Ireland, Ie

Managed complete seating system development thru launch support. Customer interface for design changes, negotiate the design change cost responsibility. Lead the engineering team to use Design for cost tool and monitored cost performance versus target during development process. Met all the cost goals for the program. Managed engineering budget of $20 Million plus for the Development program.

Mar 2012 - Jan 2015

Lead Process Engineer / Project Manager

Johnson Controls

Cork, Ireland, Ie

Led the projects with global stakeholder for engineering efficiency improvement and cost saving initiatives. Developed and Implemented prototype cost database. Identified and implemented tool waste reduction solutions as Best Business Practices (BBP). Reduced production tool wastage cost by 15%. Develop visual program risk summary to graphically displays the risk level of each seating program with reference to product development timeline. Coached global team members.

Mar 2008 - Mar 2012

Lead Design Engineer

Johnson Controls

Cork, Ireland, Ie

● Designed and developed seating system for multiple programs with various OEM’s. Designed metals, foam, trim and plastics components using cad tool CATIA V5.● Managed Bill of Materials (BOMs), Engineering Issues list, DFMEA and Design Variation approval process.● Prepared test plans and strategies (roadmaps) to meet validation requirements.● Manufacturing process selection, Datum schemes, tolerance stack studies, GD&T for assembly. ● Help win customer confidence by working onsite at competitor. Customer awarded next program to Johnson Controls.● Led team of designers to successfully design and develop 50 plus plastic parts for Honda Pilot program.

Jan 2001 - Mar 2008

Design Engineer

Visteon Corporation

Van Buren Township, Mi, Us

Designed and developed interior plastic trim component, IP, floor console, Pillar trim for commercial truck for Brazil Market. Prepared feasibility studies, packaging layouts, drawings, technical presentations for the customer.

Mar 1999 - Jan 2001

Technical Designer

Boeing

Arlington, Va, Us

Part of IRC group worked interior components. Received award for eliminating back log of rejection tags.

Apr 1998 - Dec 1998

Design Engineer

Tata Motors

Pune, Maharashtra, In

Member of Tata Safari and Tata Mini car development team. Worked on seat layouts, homologation, Vehicle body components (BIW), floor pan, door panels, front hood, pillars, Interior and exterior plastic trim components such as rear quarter trim, headliner, bumpers, IP, and vehicle level GD&T studies.

May 1993 - Mar 1998
Team & coworkers

Colleagues at Adient

Other employees you can reach at adient.com. View company contacts for 16166 employees →

PK Paulina Kwapulińska Paulina Kwapulińska Colleague at AdientZbūch, Plzeň, Czechia, Czech Republic View → GL Gregory Lamar Gregory Lamar Colleague at AdientNewnan, Georgia, United States View → ST Sandra Trsic Sandra Trsic Colleague at AdientŠabac, Centralna Srbija, Serbia View → FB Fran Barrios Fran Barrios Colleague at AdientZaragoza, Aragon, Spain View → AP Alexandre Plana Menile Alexandre Plana Menile Colleague at AdientSão Paulo, Brazil View → EL Elias Lopes Elias Lopes Colleague at AdientSão Bernardo Do Campo, São Paulo, Brazil View → JR Jessica Robles Jessica Robles Colleague at AdientAguascalientes, Mexico View → MQ Milithza Quiroz Milithza Quiroz Colleague at AdientJuárez, Chihuahua, Mexico View → SB Steve Brazier Steve Brazier Colleague at AdientTelford, England, United Kingdom View → DL David Logan David Logan Colleague at AdientKansas City Metropolitan Area, United States View →
2 education records

Ajay Sonar education

Master Of Business Administration (Mba), Program Management And Finance

Lawrence Technological University

Bachelor'S Degree, Mechanical Engineering

The Institution Of Engineers (I)
FAQ

Frequently asked questions about Ajay Sonar

Quick answers generated from the profile data available on this page.

What company does Ajay Sonar work for?

Ajay Sonar works for Adient.

What is Ajay Sonar's role at Adient?

Ajay Sonar is listed as Engineering Manager, Product Safety at Adient.

What is Ajay Sonar's email address?

AeroLeads has found 1 work email signal at @adient.com for Ajay Sonar at Adient.

Where is Ajay Sonar based?

Ajay Sonar is based in Northville, Michigan, United States while working with Adient.

What companies has Ajay Sonar worked for?

Ajay Sonar has worked for Adient, Johnson Controls, Visteon Corporation, Boeing, and Tata Motors.

Who are Ajay Sonar's colleagues at Adient?

Ajay Sonar's colleagues at Adient include Paulina Kwapulińska, Gregory Lamar, Sandra Trsic, Fran Barrios, and Alexandre Plana Menile.

How can I contact Ajay Sonar?

You can use AeroLeads to view verified contact signals for Ajay Sonar at Adient, including work email, phone, and LinkedIn data when available.

What schools did Ajay Sonar attend?

Ajay Sonar holds Master Of Business Administration (Mba), Program Management And Finance from Lawrence Technological University.

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