Aditya Sunkara

BIW Lead - MY & Cyber - Jan 2025 to Present

• Leading a team of 7 Engineers and 1 tech to handle BIW quality for both Cyber and MY.
• Working on top 1MIS topics for both models, MY - Hood to fender fitment, establishing true problem statement, failure rate, Short term and long term actions driving from 15% factory failure to 2%.
• Coaching and developing problem solving skill set for engineers on approaching problems and providing proper feedback to the stake holders.
• Highlighting importance of Gemba walks to truly understand how the parts fit together understand the failure mode.
• Coordinating and providing resources for data collection on critical trials and day-to-day gap and flush fitment.

GA - Exterior & Closures Engineer - Sept 2023 to Dec 2024

• Launch Engineer for Exteriors - Cyber. Identified multiple Design issues creating poor fitment.
• Rear Fascia to Fender flare flush Issue - identified RCA using part swap and eCube analysis to identify Design stack issue, Performed short term rework by reworking the Rear end Module and drive the long term action through design team, Failure rate dropped by 85% to below 5%.
• Launch Engineer Exteriors and Closures for NV36 - created over 100 MRT tickets from P1 to P3 identifying build issues and potential future customer complaints.
• Lead the launch builds from GA exterior and closures Quality identifying issues on the line and providing feedback to NPI and Pilot process team.
• Worked on Front end and Rear End 1MIS topics for legacy model - Headlamp to fender flush issue, identifying RCA, working on short term containments and driving long term actions from supplier and BIW dropping failure rate of 77% to below 5%.

• In charge of the LD & HD Chevy Silverado Box & Rear Closures build quality
• Working with cross functional teams – Bodyshop, Paint shop, General
• Assembly Production teams to solve build issues, ergo issues & Supplier related Issues
• Red X Project → Rear Bumper Fit condition on HD, top plant Audit issue for exterior
• Lead the project using Red x tools → Green Y run chart, Isoplot
• Multi Vari, Component Search, Paired comparison, Confirmation Tests and solved the issue by finding the root cause
• Worked on Taillamp A/V gap condition on HD – Lead the project and helped Bodyshop to found the root cause was box flexing when it is secured on to frame and top portion moving O/B by 2mm causing the defects
• Worked on multiple Interior & Exterior Squeak & Rattle Problems →
• Tailgate rattle, Rattling sound in IP, S&R noise in the front compartment & near driver seat
• Work with multiple suppliers, hold them accountable for shipping non- conforming causing DRL/DRR and Internal Audit calls and Issue SPPS & also work on cost recovery
• Worked on multiple yard campaigns – Supplier related, Plant process related – Created TIS and trained operators to review the vehicles in the yard
• Work with DREs for any engineering changes and issue PTR to run engineering trial parts before permanent changes for any issues
• Worked on top DRR issue – LD Box weld burn through, worked with paint shop, Bodyshop and ME group
• Issue was discovered happening during
• ELPO process and root cause found out presence of debris on the cart & lost contact between box and the cart.

• In charge of Underbody, body Framing and closure panels for RU Model at
• FCA Windsor Assembly Plant
• Working with cross functional teams – Resident Engineers, Plant Quality
• Supplier Quality to develop and improve process for maintaining new and existing equipment
• Worked as lead in multiple complex Kaizen – related to underbody throughput issues in Bodyshop, customer related issues with closure panels and improving overall Cpk of the vehicle
• Project Lead in solving the KUKA decking issue – Track bar to RT
• Underbody fall out were recorded 100 plus per shift, root caused, performed tooling adjustments on the underbody and results showed tremendous improvement
• Working alongside with Suppliers for incoming parts to improve underbody and BIW Cp & Cpk
• Improved the Cpk for Sliding doors from 72 percent to above 80 percent, applied WCM tools to root cause and problem solving skills to improve the hinge environment and flushness of the panels which impact our EBO
• Project Lead in solving Frame bolt#8, top issue for AWD model at FTC for the month of Nov 2020, root caused the issue and cost savings of approx.
• Project Lead for top CPA & Warranty issue for BIW – RHS Sliding to BSA over flush condition of over 3mm
• Contributed to root cause analysis to determine core reason for failures and errors
• Supported quality team members during corrective action updates
• Participated in multi-disciplinary defect reviews to discern and address root causes.

• Develop and maintain a list of critical product and process characteristics for body shop and stamping plants
• Worked with Plant quality team for water leaks from Hard tops and freedom panels
• Inspected every car going through the Fit and Finish line resulted in higher pass percentage through water test
• Percentage increased by approx.15% taking the overall pass percent to and above
• Working experience on Perceptron Vision systems – applying tolerance limits, offsets, troubleshooting, conducted correlation for the systems &
• Performed Static and Dynamic tests for each system with pass criteria of25 and 0.50 6sigma respectively
• Worked with Validation Team for performing tooling adjustments in the critical geo stations based on the data analysis and improving the overall build quality and meeting Cpk requirement for Job#1
• Worked on 35 Kaizen projects for quality control and improving build quality in the Body shop with a savings of approximately $210,000
• Tools used – 5Whys, 4W1H, Fish Bone Diagram.

• Reviewed and validated quality requirements for manufacturing planning, supplier purchase orders and engineering specifications to meet contract compliance regulations
• Daily Inspection and Audits conducted to review work progress and throughout efficiency
• Drove continuous improvement in manufacturing tasks by effectively communicating diagnostic findings to illicit production changes and encourage iteration
• Assisted Engineering staff to produce design sketches and drawings in accordance with applicable standards
• Accurately incorporate welding symbols and tolerances into design drawings
• Supported field installed equipment and implemented corrective actions.

• Basic understanding of GD&T and hands on experience on in line vision systems checking on the metal sheets on the conveyor belt
• Involved in Project discussion with Senior managers, other departments –
• Electrical, IT, Civil and clients for review and next steps in implementation
• Hands on experience with PLC and basic understanding of robot programming involved in the manufacturing of steel and other metal sheets
• Contributed to root cause analysis to determine core reason for failures and errors
• Developed and implemented process flow improvement and standardization projects.