Summary
Overview
Work History
Education
Skills
Timeline

SOMASHEKAR SETTY

Summary

Versatile professional with 16 years of expertise in diversified roles across the automotive industry. Specialize in product design and development and operational quality via a Design Release, Systems and Advance Product Quality Engineer roles. Excel cross- functionally to resolve intricate technical concerns, effectively contributing to mobility and suitability initiatives. Proficient in utilizing technical savvy to develop and launch projects including the ongoing BEV vehicle (R1T, R1S and EDV) and past efforts including Mercedes A- Class 2010, Ford 2016 F150, 2018 Ranger and 2021 Maverick. Skilled in guiding installation, commissioning, assembly line setup/sign-off and continuous improvements in vehicle production. Exude a thorough understanding in engineering first principles theory and operational execution principles. Demonstrated proficiency across vehicle commodities, including Body in White (BIW) Structures, Closures, Interior Systems Vehicle Integration and Software, with a specialization in low voltage parameter testing and mechanism integration.

Overview

17
17
years of professional experience

Work History

Staff Product Quality Engineer

Rivian
Normal, IL
05.2021 - Current
  • Spearheaded quality risk mitigation initiatives, and time-defining containment actions and developed permanent actions by leading cross-functional teams to effectively root cause for R1 and EDV vehicle lines
  • Utilize product various data, function error codes, analyzing and interpreting high-volume manufacturing data to provide statistical insights about operations from vehicle production to delivery out of the factory
  • Utilize Snowflakes SQL queries (Data Warehouse), along with Python for analysis and visualization
  • Train, coach and develop QEs in production to surpass customer expectations for overall quality attributes and vehicle craftsmanship
  • Possess experience with the automotive DVP&R cycle, requirements management, and issue tracking tools e.g.
  • JIRA, JAMA, IQ-RM, and Plato
  • Managed, Designed and commissioned of Rivian Interior cube, focusing on nominal condition evaluations of Interior Systems
  • Developed and incorporated effective Quality assurance methods and developed impactful Quality control tools in the General Assembly area
  • Design, develop, and commission Rivian Interior cubes (Nominal Bucks) for MSP-R2, R1S, R1S-Perigeen and EDV vehicles from whitepaper and commissioned/ Deployed for the Build phase as Normal and Myford(Irvine) facility
  • Effectively resolve failures (Risk mitigation) and capture learning via DFMEA, PFMEA, and control plans documented on the
  • Plato database for R1T- Vehicle Line
  • Led quality initiatives (Process, Supplier specific issue) in launching and ramping of R1T, R1S, and EDV vehicles, capacity planning, and developing timelines (Gantt charts); have closed 80% of product and process issues to active first pass yield and developed, constructed, and reported on JIRA dashboards, seamless integration with the cross-functional team
  • Determine and deliver key performance indicators (KPIs) in interior systems to align with quality targets; effectively contributed to $50k scrap reduction in general assembly via Mutilation prevention and packaging solutions
  • Lead cross-functional teams across areas to aid EDV BIW in body shop setup, implemented effective Poke-Yoke, body shop automation/ fixturing issues at CAB ASSY/ FRAMER to achieve 70% OEE at MVB build phases, and charted long-term solutions to achieve cargo door effort attribute
  • Lead and assist in the preparation of Process Failure Mode and Effect Analyses (PFMEA), Process Design Sheets, Process Flow
  • Diagrams, and component Interim PPAP signoffs as part of APQP activities
  • Supported commission of the assembly lines to active 85% quality through output at MVB and SOP phases
  • Developed Quality Assurance Method and tool to calculate process capability analysis via JMP statistical tool (Snowflakes and
  • JMP) and showcased use cases across operational shops Stamping, Body, Paint, and Plastic shops in Normal, IL impact product
  • Led and resolved battery cell weld issue on the battery pack and process capability established to have 90% through output
  • Knowledgeable and hands-on in high and low-volume manufacturing proto-typing, Line commissioning, and problem-solving through PDCA/Six Sigma needed resources to make a business impact and manage/ mentor teams needed output.
  • Leveraged statistical analysis tools to identify trends in historical data, enabling proactive measures to prevent future defects from occurring.

Design Release Engineer

Toyota, Contract - eShocan LLC
Ann Arbor, MI
02.2021 - 05.2021
  • Worked on Hard trim development of new generation Tacoma, coordinated with plant and in-house stakeholders to summarize the studio and component requirements
  • Designed and released in two milestones, released data for tooling costing, and handled the first metal cut.

Interior Systems Engineer - DRE

Ford Motor Company, Contract : ETA
Dearborn, MI
05.2018 - 12.2020
  • Performed feasibility assessments for Design Studio models and integration of vehicle Engineering specific requirements on define
  • Class A studio developments, qualified to cost justifications for manufacturing/ installation, and managed development timelines
  • Evaluated parts including craftsmanship, plastic molding, safety results, ergonomics, assembly (loading studies), and component/system packaging on IP/Hard trim commodity
  • Correlated with the current Studio Surface and component engineering to determine, deliver, and track system vehicle KPIs
  • Directed analysis and sign-off on CAD design to align with performance, cost, weight, and packaging criteria attributes
  • Secured AAR tooling sign-off using a Class A Surface
  • Produced specific deliverables on the Ford Maverick -2020 vehicle line, Creating vehicle-aligned component and system targets for function, cost, weight, and investment
  • Developed 2D Sections and 3D CAD for a balanced approach to functional/attribute trade-offs, achieved 40% cost- effectiveness through a new approach in producing effective integration and BOM break-up with robust first principles (tooling and plant process/layout) and data pertinent to component design, and achieved 100% of studio requirements
  • Effective in the introduction of new fasting bezel panels/trims and slosh molded topper panels tool feasibility from inception
  • Led cross-functional Optimize the concepts and designs with analytical and physical assessments, ensuring conformation to
  • FMVSS, delivering world-class craftsmanship and fit/finish through the proper implementation of GD&T, DFM, and offering clear risk mitigation solutions at each K-Loops feasibility milestone to the Studio
  • Organized and assessed component PPAP sign offs calculate tool efficiency and supported design quality for supplier audit events including line commissioning (main measure OEE, poke yoke at assy) at supplier setup
  • Led Integrations and launch support activity of Maverick vehicle line( NMPDC) and resolved installation/ Supplier
  • Tested and analyzed equipment design and performance feasibility to determine potential ROI.
  • Provided 2nd and 3rd level technical support and troubleshooting to internal and external clients.

Exterior Systems Engineer

Ford Motor Company, Contact : ETA, Troy
06.2016 - 10.2018
  • Conducted audits and actively participated in the build of new models, leading Trim Coordination Builds (TCB) events from prototype through to plant launch conclusion
  • Established strategic plans and procedures at all levels to ensure the exceptional quality of exterior Front-End modules (FEM) and ornamentation parts during build
  • Addressed and resolved body System
  • Fit/Function Design issues using nominal bucks, documenting them on AIMS
  • Noted emerging and chronic issues, using corporate problem-solving savvy including flow charts, mapping, cause/effect diagrams, Design of Experiments (DOE), statistical analysis, data collection, Design for Six Sigma (DFSS), Global 8D and the like to determine root causes and implement corrective actions
  • Produced specific deliverables on the Ford F150 2017, Ford Ranger 2018 model year and the Ford Escape
  • Developed product verification templates (ProVE) and visualized data to systems, calling on statistical analysis of attribute and variable data to validate supplier parts that supported tooling decisions and part changes
  • Developed and maintained strategic relationships with the Program Team, cross-functional organizations, and the supplier base in TCB builds using nominal bucks for issue resolution
  • Oversaw part/subsystem build vehicle sign-off and tool ok-to-grain sign-off, encompassing appearance approvals for components
  • Motivated and managed a cross-functional team including Exterior Trim, Latching, Glass System, Dynamic Sealing, Wind
  • Noise, Body Construction, and Manufacturing, to earn 100% PIST for body panel fits
  • Oversaw Integration-specific issues at tire-1 and plant, so to support STA and design quality for audit events including PPAPs.
  • Automated data collection activities to increase productivity.

Design Release Engineer

General Motors, Contract : ETA, Troy
03.2015 - 06.2016
  • Conducted productive benchmarking and competitive analysis, focusing on the F150 Truck
  • Integral to benchmarking, mockup creation, and development of 3D printed parts for design assessment
  • Led complete interface reviews and facilitated the release of body closure components, subsystems, and detailed designs
  • Utilized a combination of in-house design and supplier engineering to ensure positive operational outcomes
  • Integrated lessons learned into the closed-loop process for frame under glass door architecture doors
  • Took the lead in hardware integration for the door module in heavy-duty variant trucks and DFM analysis module
  • Earned DFSS Green Belt Certification by crafting feasible design solutions for door stiffness using L&L Bkt and door shatter
  • Directed a cross-functional team in addressing and resolving customer issues, including Door Fit, Door Closing Effort, Lift Gate
  • Function/Effort, and Rocker Dirt Management
  • Attained a 25% reduction in warranty costs as a result of team-implemented improvements.
  • Led multidisciplinary teams in delivering complex projects under tight deadlines while maintaining high-quality standards.

Manager

Mahindra Reva Electrical Vehicle Pvt Ltd, Body Ornamentation
05.2014 - 02.2015
  • Created and implemented requirements for Body Closure Rear Tailgate, achieving excellence in automotive body closure craftsmanship
  • Utilized DFSS methodologies to optimize designs, conducting analytical and physical assessments during program design, validation, and launch
  • Interpreted CAE simulation results, DFMEAs, and DVP&Rs, leading cross-functional teams to enhance Door Closing Efforts
  • Swiftly addressed Air Flow, Seal Load, and Latch/Striker alignments; also implemented HE Check
  • Straps and improved 8 TGW
  • Completed and released designs for body closure components, sub-systems, and detailed designs in line with Design for
  • Manufacturability, ensuring world-class execution through validated processes and tooling
  • Designed and developed an innovative method of stiffing, featured in liftgate via sheet metal insertion in LFI material mold.

Design Release Engineer

Daimler AG, MBRDI
09.2009 - 04.2014
  • Analyzed the style/clay model incorporating all functional requirements, centering on component design and release
  • Furnished crucial support during the A-class launch, effectively addressing warranty and initial build concerns promptly
  • Pioneered the development of the self-hem profile side instruction beam, overseeing creation and trials, which resulted in a patented and filed innovation
  • Crafted a Kinematic model for Side Closer Systems as a component of Door-in-White studies
  • Interpreted CAE simulation results, DFMEAs, and DVP&Rs, ensuring comprehensive technical documentation
  • Resolved issues related to Buzz
  • Squeak, and Rattling for side doors and tailgate, leading to improvements in wind cutting noise and the oil can effect during the A-
  • Class launch
  • Conducted a comprehensive study and benchmarked competitors including Audi A3 and BMW X1 regarding wind noises using the EBGL method, thus enhancing design understanding
  • Led multiple cross-functional teams, including Dynamic Sealing, Latching, Electrical Function, Body Construction, and
  • Manufacturing, to enhance Lift Gate Functions; spearheaded improvements in Manual Closing Effort, Power Lift Gate, Foot
  • Activated and Bounce Back functions
  • Managed the design and release of components for front/rear door BIW parts at MBRDI, conducting trials on the welded hem joint processes for inner and outer panels
  • Served as the leader for the 2014 C Class Project and Mechatronics Design Approach - GR Project on rear tailgate from
  • Collaborated closely with manufacturing teams to ensure smooth transitions from design to production, minimizing costly delays and errors.
  • Suggested actionable improvements to increase research and testing capabilities.
  • Additionally, spearheaded the A-Class Vehicle Launch at Rastad (Germany), overseeing warranty and continuous improvement initiatives for the closures system.

Product Design Engineer

IFB Automotive Pvt
08.2007 - 08.2009
  • Developed Window Regulator Kinematic model via ADAMS
  • Offered support for sheet metal proto tool development
  • Adhered to
  • APQP process regulations when performing audits and completing related documents
  • Guided all facets of each test rig development cycle.

Education

PGP - Business Analytics & ML - undefined

University of Texas
2020

Master of Science - Mechatronics

Vellore Institute of Technology
2007

Bachelor of Engineering - Mechanical

Visvesvaraya Technological University
2005

Certified Quality Engineer (CQE), American Society - undefined

Skills

  • Product Design & Development:
  • Closures, BIW, Exterior & Interior Components / Systems, FMVSS Regulation Compliance
  • Supplier Parts Integration, Supplier Tooling, Design Verification Plan (DVP), Technology Decision Making, CAD Design, Geometric
  • Dimensioning and Tolerancing (GD&T), Product Lifecycle Management (PLM) Release and change management, DFM, Design for Quality
  • New Product Induction and Launch: Risk Assessments (DFMEA, PFMEA) DFM Procedure Implementation, Process Capability
  • Establishment, Key Process Indications establishments, Critical to Quality (CTQ) Parameters, Cycle Time Analysis, Equipment
  • Efficiency Calculation, Production Line Commissioning & Integration, return on investment calculations
  • Production commissioning and Product Warranty: Quality Control, Continuous Process Improvement, Attribute Validation
  • Fixture Developments, MES and Service Data Review, quality control methods/ tools development
  • Technical Program Management: Interpersonal Leadership, Cross-Functional Teamwork, Professional Writing, Communication
  • Data-Driven Feedback Loops, Project Ownership, Top-Down Requirements Management, Data-driven Problem Solving using Solutions/ Infrastructure Development, Technical Collaboration and Decision Making

Engineering Tools:

  • CAD/ CAE/ PLM Tools, eg, CATIA V5, NX 9, ADAMS and Team Center 8
  • Production & Development: Design/Development of Fixtures and Gauges, GD&T Tolerances Stack Up, Root Cause Analysis (8D
  • Fish Bone, DFSS Approaches), Tooling Audits, Assy Sequence Creation, and boundary body diagrams
  • Quality: Nominal Buck Designs, Gauge R&R, Root Causing, PPAP Signoff, APQP, Control Planning, PFMEA, Statistical Process
  • Control, Process Capabilities Development, Six Sigma Application Tools, OEE, Cycle time analysis
  • Programming & Statistics Tool: Python-Data Analytics, Tableau, JMP, Data Warehouse (Snowflakes)
  • Regulatory & Design Requirement Exposer: Closers FMVSS 206/214/302/571, ISO 26262, DV Criteria and test setups, Design
  • Material Exposed to Steel, Aluminum forming and casting, Composites (LFI & SMC), Plastics and DVA’s
  • Machine Learning toolbox: Linear Regression Analysis, Machine Vision (Techniques in Python)
  • Additional: JIRA, PLATO, Kinematic/Dynamic Simulation - NX Nastran, Minitab, Linear Regression Analysis, Hyper Form 8-Blank

Timeline

Staff Product Quality Engineer - Rivian
05.2021 - Current
Design Release Engineer - Toyota, Contract - eShocan LLC
02.2021 - 05.2021
Interior Systems Engineer - DRE - Ford Motor Company, Contract : ETA
05.2018 - 12.2020
Exterior Systems Engineer - Ford Motor Company, Contact : ETA, Troy
06.2016 - 10.2018
Design Release Engineer - General Motors, Contract : ETA, Troy
03.2015 - 06.2016
Manager - Mahindra Reva Electrical Vehicle Pvt Ltd, Body Ornamentation
05.2014 - 02.2015
Design Release Engineer - Daimler AG, MBRDI
09.2009 - 04.2014
Product Design Engineer - IFB Automotive Pvt
08.2007 - 08.2009
University of Texas - PGP - Business Analytics & ML,
Vellore Institute of Technology - Master of Science, Mechatronics
Visvesvaraya Technological University - Bachelor of Engineering, Mechanical
- Certified Quality Engineer (CQE), American Society,

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