Lohit Machanuru

• Led the design, engineering, and development of central console and lower-cabin trim components and ducts for the latest Honda and Acari SUV models. Iterated design concepts based on feedback and performance evaluations, overseeing material selection, CAD modeling, prototyping, and testing to ensure compliance with Honda's stringent quality standards and production specifications.
• Created master sections and conducted layout checks with surrounding parts, collaborating with cross-functional teams to conceptualize and design interior components. Ensured components met aesthetic, functional, and ergonomic requirements, resulting in a 15% improvement in assembly efficiency and a 10% reduction in production costs through optimized design solutions.
• Conducted research on materials suitable for interior trim applications, considering factors such as durability, cost, weight, and sustainability. Evaluating material samples through testing and analysis to ensure compliance with Honda's quality and safety standards.
• Liaised with suppliers to assess component feasibility, managing the manufacturing process and ensuring strict compliance with Honda's specifications and quality standards.
• Traveled to supplier facilities in North America to gain firsthand knowledge of manufacturing processes, identify cost-saving opportunities, and ensure efficient product development.
• Optimized floor spacer design for LVL-1 assembly, resulting in a cost reduction of $5 per unit while maintaining performance and engineering requirements.
• Streamlined carpet design by minimizing water-jet trim openings, achieving a 15% reduction in cycle time and enhancing production efficiency.
• Led development of modular central console architecture with 40% parts commonality across SUV variants reducing tooling investment and assembly efficiency.

Components Worked with:

Floor Carpet and Mats, Heater Ducts, Lower Cabin Hard trims, Console cover AS/DS, IP Under cover AS

• Lead product design and development of Door trim and body side trim components for Nissan, Honda, Canoo EV from concept phase to the launch of the vehicle.
• Also handled Overhead console, cowl-cover, Headliners pre-production and post-production issues.
• Interacted with Nissan design studio on the surface validation and interior trim development, considering the packing criteria of interior trim components with the surrounding components.
• Incorporated DFM and DFA feedback from manufacturing and process engineering into design concept.
• Performed layout checks and creating master sections to check fit and finish conditions with mating and surrounding components and negotiation with Customer for feasible design based on DFM, DFA, GD&T, cost analysis, cost impact, etc.
• Conducted packing study and created B-side features and made sure design meets customer fit and finish requirements and standards.
• Validated functional aspects of design concept using 3D printed parts, low-volume prototypes, and mock-up parts.
• Validated FMVSS requirements by performing CAE analysis studies for side impact testing and head impact testing.
• Coordinated closely with cross-functional teams-tooling, manufacturing, production, quality, testing, and warranty engineers-to drive continuous process improvements and ensure alignment with design specifications, customer requirements, and assembly standards.
• Worked on NVH, Door Topcoat shape optimization, other cost reduction activities on interior components and submitted cost saving ideas to Nissan.
• Designed snap fit assembly system reducing fastener count by 60% while maintaining structural integrity.
• Created RFQ documents and provided cost saving ideas for Future model vehicles, also led automotive interior component design from concept to launch, specializing in door trim and body side components for major OEMs while ensuring FMVSS compliance.
• Resolved over 20 parts build and testing failure issues for the 2022 Nissan Frontier, primarily identified after first-off tool part builds and testing. Conducted root cause analysis, engineering studies, and C/M releases, ensuring thorough follow-up until OP/OT parts were adopted.

Components Worked with:

Door Trims, Body side Trims, Cowl-cover, Overhead console, Headliners, FR/RR scuff plates and support

• Managed team of associates on Honda Accord production line for installing sunroof, tail lamps, headlights and air-bag.
• I was responsible for part of production line and meeting department goals and standards on quality, productivity, cost, and safety.
• Planned and established work schedules, assignments and ensure associates are working within the Honda guidelines and manage new hire evaluation.
• Took lead and ensured there is no down-time and always met the end of the day target.
• Ensured all preventive maintenance is done on all equipment in area of control.
• Coordinated with material handling team to ensure there is no shortage of parts and kept the line running.
• Gave quick and timely feedback to supervisor on all exceptions regarding productivity, downtime, quality and safety.