Summary
Overview
Work History
Education
Skills
Websites
Certification
Timeline
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CHIRAG SUNIL GANDHI

Summary

Results-driven Manufacturing Engineer with 6+ years of experience in high-volume automotive and EV environments. Certified Six Sigma Green Belt with expertise in automation systems (FANUC, UR), PLCs (RsLogix5000), MES/PLM tools (Teamcenter, Nysus), and Lean Six Sigma methodologies (DMAIC, PFMEA, SMED). Proven track record in APQP, launch readiness, OEE improvement, defect reduction, and deploying smart manufacturing solutions through cross-functional collaboration and data-driven engineering.

Overview

9
9
years of professional experience
1
1
Certification

Work History

Manufacturing Engineer I

IAC Group North America Inc.
03.2022 - 01.2024
  • Executed Make/Buy strategy for in-house Ultracruise HL assembly, developing $300K robotic glue dispensing & hydraulic punch equipment; validated via FAT/SAT and IQ/OQ, reducing per-unit HL cost by $2.75 and supporting APQP/SOP launch.
  • Enhanced operator safety across 2 HL automation lines by designing RsLogix5000 ladder logic for stop alarms, auto-line shutoff Poka-Yokes, and LOTO training SWI, ensuring OSHA compliance.
  • Improved TAKT and reduced defect rates by designing an HL defect tracking Power BI dashboard and implementing DMAIC with 5Why RCA, Minitab DOE, and operator training, achieving 93% FTT.
  • Developed EOL HL testing system (7% GRR) by integrating UR20 Cobot with PLC-controlled Poka-Yoke fixtures and a transducer stiffness check, improving Cpk to 1.5 and accelerating APQP validation.
  • Achieved 30% assembly efficiency for 12K-unit SOP volume by performing Run@Rate analysis, redesigning AutoCAD line layouts, and simulating material/manpower flow in Arena v16.
  • Automated HL TPM Kanban tracker and KPI dashboard in MS Excel using Python, enabling real-time visibility and achieving 91-95% PM compliance, reducing unplanned downtime and improving OEE by 5%.
  • Increased line throughput by 20.83% for critical HL Waterjet trimming via Gemba-driven LPA, leading SMED tooling changeovers, and optimizing FANUC Mi10 Roboguide cutting paths (14.24% cycle time reduction).
  • Drove $354K Edge-Fold tooling development for HL NMI using DFM, ASME Y14.5 stack-up analysis, and Teamcenter PLM for ECCs; ensured dimensional integrity with Zeiss CMM/GOM for PPAP readiness.
  • Configured MBOMs and routings in Teamcenter PLM; integrated PFMEA controls and digital work instructions via Nysus MES for traceable line validation and on-time PPAP approvals.
  • Engineered Shoplogix IIoT dashboards with MES Andon escalation and QAD ERP label-scan backflush, eliminating $70K-$85K in HL NVA raw material waste through real-time variance alerts.
  • Redesigned HL returnable packaging in SolidWorks under ECN governance, applying Zero Defect methodology and ISTA-verified validation to eliminate logistics failures, preventing $200K in warranty claims.

Packaging Engineer

Kirchhoff Automotive
10.2020 - 01.2022
  • Designed and implemented custom packaging (returnable racks, totes, bins, expendables) in SolidWorks for new product launches, ensuring ASTM/ISTA compliance and reducing packaging waste by 10%.
  • Led PFEP deployment in SAP S/4HANA, improving warehouse space utilization by 57% and achieving $900K in logistics cost savings via packaging optimization and LTL/FTL efficiencies tracked on an SQL-driven Tableau dashboard.
  • Developed a $150K packaging forecast model using Newsvendor methodology, cutting material inventory by 33% and standardizing expandable packaging with vendors for cost-effective, sustainable solutions.
  • Supported 20+ production cells by aligning packaging with ergonomic handling and automation requirements, maintaining OSHA compliance, and advancing lean manufacturing and sustainability initiatives.

Manufacturing Process Engineer

Honda Motorcycles and Scooters India PVT Ltd.
07.2016 - 06.2018
  • Boosted OEE by 12% for automated torque/weld stations by deploying preventive maintenance, TPM schedules, and an urgent breakdown escalation process for 24/7 production.
  • Engineered magnetized robotic end effectors in SolidWorks using GD&T blueprints, DFM, and ECNs to improve serviceability, reduce tool wear, and ensure 100% weld integrity in copper clip placement.
  • Leveraged JIT material flow for KTF/KWP launch (APQP) using Arena VSM, MODAPTS time studies, and AutoCAD FIFO Kanban, boosting AGV utilization and achieving a 12% ramp-up throughput gain.
  • Reduced torque station non-conformances by integrating Atlas Copco QST tools with MES-triggered OK/NOK Poka-Yokes and master gauge validation; authored PFMEA/Control Plans for closed-loop QMS feedback.
  • Led EOL system development across 15 BIW weld cells, integrating Cognex In-Sight cameras with CompactLogix PLCs and MES VIN-tracking, enabling fastener traceability and improving cycle reliability by 20%.
  • Configured FANUC Arc Mate MIG cells with Lincoln Power Wave R450 via Ethernet/IP; executed TCP/IP and wire touch calibration in ROBOGUIDE, implementing seam tracking to reduce spare rework by 35%.
  • Managed a $350K CAPEX weld fixture refurbishment RFQ by developing SOWs and automating SAP-CRM response workflows using Excel VBA, reducing procurement cycle time by 30%.

Manufacturing Quality Engineer Intern

The Supreme Industries Ltd.
06.2015 - 05.2016
  • Achieved 100%-dimensional compliance for 18+ critical plastic vehicle parts by performing GD&T analysis and CMM data validation for pre-production builds.
  • Reduced launch delays by 30% by leading Tier-2 supplier qualifications (APQP), executing PPM/KPI-based audits, and ensuring 100% PPAP approval using Gantt-driven timelines.
  • Improved First Pass Yield by 22% and gauge reliability by 40% by executing Gage R&R (MSA), enhancing fixture calibrations, and deploying corrective gauge modifications.
  • Cut $95K in annual warranty costs and reduced SPPS issues by 60% through automated non-conformance analysis using KNIME, integrating 8D, Reverse FMEA, and One-Point Lessons.
  • Ensured IATF 16949 & CQI-8 compliance by supporting internal audits, conducting PFMEA reviews, and training operators in layered process audits.

Education

Master of Science - Industrial Engineering

Wayne State University
Detroit, MI
07.2020

Bachelor of Science - Mechanical Engineering

Pune University
Pune, India
06.2016

Skills

  • FANUC Robots (Roboguide)
  • Universal Robots (UR)
  • PLC Programming (RsLogix5000, CompactLogix)
  • Robotic End Effector Design
  • Vision Systems (Cognex)
  • MIG Welding (Lincoln Power Wave)
  • Teamcenter PLM
  • Nysus MES
  • SolidWorks
  • AutoCAD
  • Minitab
  • Power BI
  • Arena Simulation v16
  • MS Excel (Python, VBA)
  • SAP S/4HANA
  • QAD ERP
  • Shoplogix IIoT
  • SQL
  • Zeiss CMM
  • GOM Inspect
  • Lean Six Sigma (DMAIC, PFMEA, SMED, 5Why)
  • APQP
  • PPAP
  • Launch Readiness
  • OEE Improvement
  • First Time Through (FTT)
  • Cpk
  • SPC
  • DFM/DFA
  • GD&T (ASME Y145)
  • Gage R&R (MSA)
  • Poka-Yoke
  • Kanban
  • JIT
  • Value Stream Mapping (VSM)
  • TPM
  • ISTA Packaging Standards
  • IATF 16949
  • CQI-8
  • 8D Problem Solving
  • Root Cause Analysis (RCA)
  • High-Volume Assembly
  • EV Component Manufacturing
  • Weld Cell Integration
  • Torque Control Systems
  • Packaging Design & Optimization
  • Material Flow Optimization
  • Cost Reduction
  • Make/Buy Analysis
  • Tooling Development & Validation (FAT/SAT, IQ/OQ)
  • EOL Testing
  • Line Balancing
  • Cycle Time Reduction

Certification

  • Six Sigma Green Belt
  • Certified Quality Engineer (CQE)

Timeline

Manufacturing Engineer I

IAC Group North America Inc.
03.2022 - 01.2024

Packaging Engineer

Kirchhoff Automotive
10.2020 - 01.2022

Manufacturing Process Engineer

Honda Motorcycles and Scooters India PVT Ltd.
07.2016 - 06.2018

Manufacturing Quality Engineer Intern

The Supreme Industries Ltd.
06.2015 - 05.2016

Master of Science - Industrial Engineering

Wayne State University

Bachelor of Science - Mechanical Engineering

Pune University

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CHIRAG SUNIL GANDHI