Sanjeet Dalai
Marysville
Summary
Accomplished Design Engineer with extensive experience at Honda America, specializing in vehicle assembly structures and tool design. Proven track record in project management and concept generation, driving cost-effective solutions and enhancing product performance. Adept in sheet metal analysis and fostering cross-functional collaboration to achieve design excellence.
Overview
20
20
years of professional experience
1
1
Certification
Work History
Design Engineer III
Honda America
Ohio
03.2025 - Current
- Generated value analysis ideas for body systems through competitor vehicle teardown assessments.
- Coordinated with suppliers for testing and reporting of value analysis concepts.
- Conducted cost and investment forecasting for upcoming models while performing detailed competitor analysis. .
- Utilized CATIA to study current layouts and part specifications, developing concepts for supplier discussions.
- Analyzed part details and associated costs to estimate competitor pricing and formulate strategies.
- Evaluated spot weld sequences and painting methods to derive value analysis ideas.
Design Release Engineer
Nissan Technology Center North America
FH
06.2023 - 02.2025
- Worked in Body Design on trim and BIW panels, including the hood lock, hood insulation, windshield, rear pillar inner, exterior back pillar, and rear combination lamp housing panel, supporting design and development for new Nissan programs.
- Developed new hood seals, latches, and inner panels for next-generation platforms.
- Designed windshield glass to meet homologation requirements, incorporating new camera mounts, and wiper layouts.
- Performed DFMEA studies based on newness assessments, and created DVPs for multiple components.
- Prepared GD&T and stack-up analyses for mounting parts, and conducted fit-and-finish studies.
- Created master sections to evaluate layout, mounting feasibility, and manufacturability, considering load paths, datums, and spot weld locations.
- Coordinated with vehicle planning teams to achieve cost, timing, and quality targets for new programs.
- Collaborated with testing, CAE, and supplier teams to ensure that vehicle performance requirements were met.
- Led design reviews with suppliers to achieve performance targets for NVH, rigidity, and crashworthiness.
- Work with suppliers to build the prototype, discuss with the supplier quality department regarding the planning of jigs, fixtures, and tooling requirements, and testing for the newly developed hood latch, rad core support, etc.
- Analyze the supplier quote for tools, jigs, and fixtures quoted, and negotiate with purchasing.
- Prepared RFQs, specification sheets, cost summaries, BOMs, and tooling kickoff orders.
- Negotiated technical specifications, tolerances, and design proposals; analyzed supplier quotations for cost and process efficiency; and prepared budget transfer requests.
- Followed up with suppliers to verify part quality, test conformance, and negotiate countermeasures.
- Implemented VO (Value Optimization) initiatives, tracked budget requests, and led cross-functional meetings with plant teams to execute cost-reduction items.
- Maintained project data, budgets, and status updates for regular reviews with vehicle program management.
Design Release Engineer
Stellantis Inc
Auburn Hills
12.2018 - 06.2023
- Contributed to the Instrument Panel–Cockpit module development for the Ram and Pacifica vehicle lines.
- Coordinated testing activities with suppliers, performed root cause analysis, and ensured adherence to project timelines.
- Managed the change management process, including releasing CNs, maintaining EBOM trackers, and updating PLM data.
- Served in the Advanced Concepts Engineering group, responsible for the winch design, wiring routing, and clearance calculations for brakes, fuel lines, and heat sources.
- Supported new development programs for the Jeep vehicle range, performing clash and clearance studies, and collaborating with transmission, exhaust, and packaging teams for feasibility reviews.
- Directed development-phase activities through weekly cross-functional meetings, prioritizing issue lists, and tracking progress to meet timelines.
- Liaised with suppliers to obtain PSWs, ensure APQP compliance, and resolve manufacturing and production concerns in Engineering Change meetings.
- Ensured design specifications and standards compliance by following set design checklists and databases.
- Prepared DFMEA, DVP, and Failure Analysis/5-Phase reports, conducting thorough root cause analyses.
- Collaborated with the Advanced Concepts Engineering (ACE) team to generate underbody design and manufacturing concepts, performing layout and clearance analyses in Vismockup for PHEV and EV platforms.
- Packaged exhaust, fuel, and brake lines per thermal and clearance requirements.
- Evaluated pressure drop characteristics for new exhaust designs, and optimized mounting layouts.
- Partnered with crash, NVH, and durability teams to enhance Body-on-Frame (BOF) vehicle performance.
- Assessed seatbelt comfort for multiple occupant sizes across all seating rows, using ergonomic software (RAMSIS) within the internal restraints team.
- Coordinated with the seat lab on SLED tests, H-point determination, seat belt anchorage zones, and reach studies for various manikin sizes.
Designer
Manor Tool and Die
Windsor
09.2017 - 08.2018
- Developed process plans and conducted manufacturability analysis for BIW parts using Autoform.
- Created draw surface models in Rhinoceros and prepared layouts in SolidWorks 2016.
- Calculated yield for blank utilization by preparing blank nesting processes.
- Performed die surface morphing and analyzed spring back using Autoform software.
- Established method plans based on GD&T specifications, securing client approval.
- Coordinated with try-out team to ensure manufacturability of cold and hot stamped parts.
- Processed BIW parts for progressive transfer and tandem presses, optimizing blank layout and trim lines.
- Executed GD&T studies and initiated cost and quality optimization efforts.
Senior Technical Lead / Designer
Tata Technologies Ltd.
03.2016 - 06.2017
- Designed underbody brace for the Jaguar and Land Rover Evoque Convertible.
- Translated strategic and functional requirements into technical specifications and helped establish performance targets for stiffness, NVH, torsional rigidity, and other parameters.
- Conducted benchmarking of competitor vehicles using A2MAC1 to define performance parameters and positioning.
- Monitored resource planning, project costs, and quality using GEM software.
- Developed GD&T, DFMEA, and initial BOMs in line with design gateways, and coordinated with suppliers on part feasibility, as well as with CAE teams for performance optimization.
- Managed a team of 15-part design engineers, overseeing the quality and timely delivery of their work.
- Led project management activities, resource planning, and preparation of metrics and reports for managerial review.
Manager
Maruti Suzuki India Limited
05.2015 - 03.2016
- Conducted benchmarking of competitors’ vehicles for Body-in-White (BIW) and trim parts, gathering, analyzing, and presenting technical data to management.
- Evaluated competitors’ design strategies, cost advantages, special features, and manufacturing processes.
- Analyzed BIW structures to assess crashworthiness, NVH, and durability performance.
- Coordinated with Test and CAE teams to validate design ideas and implement cost-effective solutions.
Assistant Manager / Designer
Renault Nissan Technology and Business Centre - Chennai, India
01.2012 - 05.2015
- Designed gussets for small overlap crash (25% offset) and developed concepts for small overlap crash restraints in compliance with IIHS regulations.
- Coordinated with prototype, test, and CAE teams to validate designs and ensure compliance with Global and Euro NCAP regulations.
- Worked on the Datsun Go project, focusing on crashworthiness of the front structure for South Asian markets.
- Optimized local panels within the floor structures of the Nissan Skyline “Z.”
- Designed the rear floor structure for Nissan CMF platforms.
- Prepared benchmarking reports, weight comparisons, and other performance indices to support design decisions.
Manager / Designer
Tata Motors Ltd.
03.2006 - 01.2012
- Worked in BIW/Trim Design at the Engineering Research Centre (ERC) and in the CAE department within Production Engineering.
- Created the process plans for the 2D/3D machining of die blocks for stamping dies and base matching weld fixtures.
- Worked on the formability simulation of Sheet metal components & decide the method plan to achieve the desired quality with minimum set of dies.
- Developed Draw surface for stamping simulation using Pamstamp, coordinated with die tryout to get the optimized part.
- Conducted sheet metal panel die simulations for passenger and commercial vehicles in the Production Engineering Division of Tata Motors Ltd.
Education
Master of Science - Engineering Management
University of Windsor
Windsor, Ontario, Canada01.2021
Post-Graduation in Tool Design (PGTD) -
Central Institute of Tool Design (CITD)
Hyderabad, India01.2006
Bachelor of Engineering (B.E) -
Andhra University
Visakhapatnam, India01.2003
Skills
- Vehicle assembly structures knowledge
- Tool and product design
- Concept generation and design
- Project management
- Sheet metal analysis
- Design for six sigma
Certification
Professional Engineering Certification, Professional Engineers Ontario (PEO), 100533737
Timeline
Design Engineer III
Honda America
03.2025 - Current
Design Release Engineer
Nissan Technology Center North America
06.2023 - 02.2025
Design Release Engineer
Stellantis Inc
12.2018 - 06.2023
Designer
Manor Tool and Die
09.2017 - 08.2018
Senior Technical Lead / Designer
Tata Technologies Ltd.
03.2016 - 06.2017
Manager
Maruti Suzuki India Limited
05.2015 - 03.2016
Assistant Manager / Designer
Renault Nissan Technology and Business Centre - Chennai, India
01.2012 - 05.2015
Manager / Designer
Tata Motors Ltd.
03.2006 - 01.2012
Master of Science - Engineering Management
University of Windsor
Post-Graduation in Tool Design (PGTD) -
Central Institute of Tool Design (CITD)
Bachelor of Engineering (B.E) -
Andhra University