Sajjad R. Email and Phone Number

• Responsible for the development and execution of robust verification and validation plans for Power Electronics (PIM, APM, OBCM) and its components that comprehend vehicle level features and systems that drive cross-functional requirements and integration.• Worked with technical experts in development of realistic reliability requirements for Power Electronics (PIM, APM, OBCM) and its components (Reliability Allocation) based on actual customer usage data.• Performed warranty analysis using data from different sources. Worked with engineering, supplier, and plant in root cause analysis, determine breakpoint and coverages.• Worked with suppliers at different stages of program so they can have better understanding of testing/reliability requirements, pass/fail criteria, equipment requirements, equipment’s’ calibration, DFMEA, etc.• Provided mentorship to young engineers in development/revising damage models/test profiles, DFSS/ATW projects, DFMEA, Accelerated Testing plans, Acceleration Factor calculations, etc.• Worked with Big Data (OnStar, CTF, Warranty, NOAA, and DoT) and developed customer usage profiles, USA/China weather study and correlation between field to proving ground damage.• SME for all reliability, statistics, Big Data, accelerated testing and AEC (Automotive Electronics Council) qualification related questions.• Facilitated and participated in system/component DFMEAs, validation planning, DRBTR and incorporated findings and learnings into validation plans.• Trained young engineers in DFR concepts, Weibull Analysis, Statistical testing, DFMEA, Accelerated Testing.

• Coordination (P&T disciplines and others) and facilitation of FMEA, PTIE (Proactive Threat Identification Engagement) and Asset Management Review workshops at different manufacturing sites. • Helped manufacturing sites and upstream business on making informed decisions to prevent equipment, process, & human failures using different reliability techniques. (FMEA, RAM, Weibull Analysis, CROW-AMSAA)• Training and continuous support to site Reliability Engineers in reliability tools (Weibull Analysis, CROW-AMSAA), GUS (Global Utilization System) Data analysis, and MTA (Mitigate Threats to Availability).• Performed Reliability, Availability & Maintainability (RAM) studies for Downstream Manufacturing and Upstream business using TARO, MAROS and AvSim. This helped setting future goals and unit targets.• FMEA facilitation support to Shell DS manufacturing, upstream, suppliers and other joint ventures.• Work with R&D and project teams from early stages to set reliability targets on new programs, failure elimination by FMEA, coordination with suppliers to develop right test, and agreement on pass/fail criteria.• Helped manufacturing sites in identifying chronic issues by doing RMF Health Checks

• Developed long-term site wide Reliability Plan & Strategy to ensure capturing of all the major threats and their mitigation. Plan showed, timing, resources required and improvement expected.• Worked with different disciplines in developing site wide bad actor process and reliability strategy.• Provided facilitation for RCM Equipment Criticality Identification Sessions, and MTA (Mitigate Threats to Availability) to help the Production Teams in rejuvenating the MTA process.• Facilitated monthly RST (Reliability Steering Team) meetings, presented site’s current situation to make informed decisions.• Brought reliability culture to the site by showing how the use of reliability tools solves problems.• Evaluated the effectiveness of reliability improvement strategies & tactics [Crow-AMSAA Plots]

• Single point contact for all the Reliability related items for North America and Globally.• Enhanced Reliability on new product using DFSS / DFR tools. Assisted and provided guidance in developing Reliability Requirements, DVP&R (Design Validation Plans and Reports) and proper FMEAs.• Mentoring engineers from the early stages of the programs for accurate interpretation of the results from different analyses (FMEA, FTA, DOE, and Testing) to make sure programs will meet reliability and long-term durability goal.• Used warranty data and developed various reliability models to show if giving extended warranty on certain products is profitable.• Developed reliability models based on test data for Defense related projects to show if the product is meeting reliability requirements, and how much more testing needed to satisfy the requirements. • Developed Reliability Growth plots for various products going through durability testing. Plots show change in reliability over time and if the product is maturated enough to market.• Rigorous validation of projects using DFSS/DFR tools and identifies new programs with elevated risks that require reliability analysis.• Monthly reporting to Vice President/Directors on reliability concerns, failure trending and corrective action activities (8D). (Weibull Analysis & Crow-AMSAA)• Active participation / facilitation of FMEAs and problem solving (8D) meetings on design related issues from testing, field and plant, and drive them to proper closure.• Educated engineering community from North America and Global facilities in DFSS/DFR concepts and tools (FMEA, FTA, Reliability Prediction, Reliability Growth, and RCCA).

• Chair daily FRB (Failure Review Board) meetings and maintain database on failures happened during daily production, field returns, and qualification testing for proper root cause corrective action (RCCA). • Performed Reliability & Maintainability prediction using models, test data and field return data to ensure programs are meeting their reliability requirements. (MIL Standards, Weibull Analysis & Crow-AMSAA)• Responsible for facilitation and coordination of different analyses e.g. FMEA, FMECA, FTA.• Work with program development team (PDT) to set reliability requirements for new programs.• Daily / Weekly presentation and reporting to production managers, program management and executive staff on failure trends, current and long terms FRB actions, and failed product RCCA activity.• Responsible for writing Failures & Corrective Action Reports (FACAR) for customer (DoD).• Worked with technicians and assemblers to develop troubleshooting matrix for troubleshooting and root causing of failed product.• Coordinate with other departments in scheduling, performing, and evaluating the testing / troubleshooting.• Calculated acceleration factors and performed HALT, and developed HASS methods for product screening.• Tracking of all failed material (current production, field return & failures during testing) comes under FRB.

• Defined and implemented FMEA process, which includes FMEA execution, participants selection, how to make FMEA a valuable activity, cross linkage between FMEA and other documents (drawings, PFMEA, control plans, DVP&R), time tracking, and transfer of lessons learned from one FMEA to others. • Successfully defined and executed different failure reporting & corrective actions systems which offers an at a glance view of all open, late and completed design issues. (FMEA Reporting, 8D, PKMS)• Introduced a new approach, Family FMEA, to capture same family of FMEAs in one file, which resulted in more than 50% time reduction. Template was approved by TS auditors and used as an example in their manual.• Led and implemented process for Knowledge Management System. System resolves day-to-day issues and capture tribal knowledge to assist new engineers to learn faster.• Developed presentations to train Product Engineers, Designers, suppliers and other engineering communities in physics of failures, which led to proper and robust designs.• Responsible for ensuring department meets TS 16949 requirements.

• Performed FMEAs on different systems / subsystems to increase the probability that potential failure modes and their effects on system and vehicle operations considered in the design/development process and properly addressed in Vehicle Technical Spec (VTS) and Sub-System Technical Spec (SSTS).• Performed reliability & warranty prediction using test data and field warranty data.• Trained Product, Manufacturing, Validation and other engineering communities in Reliability concepts (FMEA Customer Education).• Responsible for contracting and performing Manufacturing Reliability & Maintainability (MR&M) projects for vehicle underbody, for all GM North American plants (Equipment Reliability, Availability, and Maintainability).• Surveyed within GM (MLCG) and developed FMEA training manual. Manual define purpose, process and position of GMNA regarding FMEAs. Educated various departments including Engineering, Validation and Manufacturing about GM FMEA policy and process.• Identified proper Key Product Characteristics (KPC) and Key Control Characteristics (KCC) and deployed them through recommended actions in FMEAs.