Responsible for occupant package and human factors engineering for all Mahindra vehicles designed in North America. Duties include: - ensuring statutory compliance of all vehicle features related to vision, seating, restraints, instruments, drivers controls, lamps, bumpers, interior surfaces and pedestrian protection- setting up occupant packaging requirements for all vehicles under development- development and maintenance of the vehicle package drawing and all associated dimensional measurements- performing physical evaluations of vehicle properties to determine user comfort and convenience levels- performing competitive benchmarking to establish target packaging performance levels- reporting package engineering compliance to program targets- building and evaluating human simulation models to determine expected vehicle design and production process performance levels- providing guidance on solving human factors issues for both product design and operations teams- coordinating research activities with partner academic institutions including U of M Transportation Research Institute (UMTRI) and the Center for Creative Studies

Responsible for directing the vehicle and component packaging and design of REEV (Range Extended Electric Vehicle) powertrain systems for light duty Ford truck and Chinese commuter bus applications. Work includes managing the:- Creation of innovative package solutions for each vehicle application- Design of part geometry for all component systems- Documentation of design standards and procedures- Administration of the Catia CAD system and Smarteam PDMResponsible for designing the REEV component assembly and vehicle conversion process plans for powertrain and vehicle production at the company’s headquarters factory site and planned satellite locations within the PRC. Work includes both creating and managing the creation of:- Factory designs including architectural improvements- Production process flow and work-cell design studies- Value stream analysis and logistics studies- Production Bills-of-Process- Direct and indirect labor cost estimates- Material management and containerization studies

Responsible for developing, implementing and managing the total vehicle package design for the Model S Electric Vehicle program. Work included:- Establishing vehicle packaging targets and requirements for the product development team - Packaging all occupants and equipment, including maintenance of the master package drawing- Ensuring conformance with all national and international regulations related to vehicle packaging- Tracking and reporting vehicle weight, dimensions, completeness, regulatory conformance and open issuesResponsible for developing design concepts and labor estimates for the Model S EV Trim/Chassis/Final production operation. Work included:- Process flow studies - Production Bill-of-process- Line balancing and over-speed studies- Takt time, scheduling and direct labor requirement studies

Responsible for designing and implementing the North American market penetration and development strategy for Karmann USA. Work included: - Forecasting market shifts and identifying emerging business opportunities - Acquiring new business for the company through the competitive bid process (awarded 2007-10 Mustang account)- Influencing customer decision makers through active involvement with their planning teams - Developing and presenting innovative product proposals to support acquisition of new business- Counseling design engineers on best practices related to convertible vehicle design and development.Also responsible for implementing GM QSB and developing lean manufacturing strategy for Karmann USA including:- Accessing current production states and designing future states- Training team members in QSB and lean thinking, processes and techniques- Conducting process control studies, performing experiments and making adjustments as required - Monitoring system performance and reporting conformance to key performance metrics- Leading supplier quality improvement tasks force activities at several high-risk vendors

Responsible for all product research, design and development at the concept and feasibility levels. Work included:- Forecasting product trends and shifts in technology- Preparing and presenting R&D funding proposals - Designing and developing new and innovative product solutions (four unique roof system solutions developed three of which were patented including designs for the Pontiac Solstice and Ford Mustang)- Accessing risks posed by new products and identifying mitigation strategies- Participating in corporate level R&D strategy teams including benchmarking and materials- Developing the R&D core staff and championing continual improvement through the use of Kaizen methods

Responsible for the design of all open-air roof products and the administration of all engineering processes at the corporate level. Work included:- Directing the activities of over 80 employees in the various niche vehicle design teams- Managing the CAD/CAE/CAM, Change Control, Library and Technical Publications groups- Designing new and innovative roof systems and vehicle applications (including systems for the BMW Z3, Toyota Celica, Paseo, Camry Solara and Lexus SC400 showcar)- Formulating and administering all engineering policies, procedures and quality metrics- Serving on the corporate quality, IS and strategic planning subcommittees- Supervising the design and construction of all show, prototype and bespoke properties - Training corporate staff in lean thinking and mechanical systems design - Advising the business development group on what technologies to offer customers