Vaibhav Verma
South Lyon,MI
Summary
Results-driven Automotive Project Manager with over 13 years of experience in Product & Process development, integration and management of automotive products across various platforms. Strictly adheres to both client-provided technical & contractual requirements and internal business revenues & goals.
Overview
15
15
years of professional experience
1
1
Certification
Work History
Program Manager
Faurecia Clean Mobility
Auburn Hills, MI
09.2025 - Current
- Mobilized the operations of a diverse team of 12 professionals with a wide scope of responsibilities.
- Utilized quality, development Engineering, manufacturing engineering, and sales skillsets to determine the best outcomes for escalated concerns from teams in five different areas.
- Headed the successful product launch and plant hand-off of three separate programs that delivered $500M in total sales; consecutively directed the program management APQP system.
- Maintained launch account control for Capex, Opex and ED&D outpacing budget objectives for all programs.
- Assumed responsibility for a crisis launch; advanced improvements to Open Interest (OI) and Internal Rate of Return (IRR), while managing an upfront to zero degradation.
Lead Engineer
Faurecia Clean Mobility
Farmington Hills/ Auburn Hills, MI
12.2020 - 08.2025
- Lead & Coordinated with cross functional teams the product development, ADVP&R and integration of exhaust systems for multiple vehicle platforms, ensuring alignment with customer on design freeze deliverables, performance, and regulatory standards.
- Lead the team of Designers, Product & Process Engineer by holding final responsibility for design (CAD, Clearance Analysis), development (CFD, FEA, NVH, Converter Canning & Mixer(diesel engine)) and implementation (Manufacturing Feasibility Analysis) of multiple GM exhaust platforms by being a face to the customer.
- Lead new acquisitions lifecycle by providing Costed EBOM's, ED&D, COT, CAPEX, Launch cost, Overheads & Labor. Provided cost justifications to customer during quote reviews and tech Reviews.
- Managed project engineering timelines, engineering budgets and resource allocation within various platforms resulting in a 20-25% reduction in development cycle time.
- Lead development of Technical Specifications and testing procedures using customer inputs by performing a lot of virtual validations thus reducing physical testing cost. Lead on time delivery of customer prototypes
- Implemented continuous improvement strategies and collaborate with suppliers that enhances exhaust system durability, performance by (~20%) and reduces cost by (~15%) while maintaining quality.
- Drove technical innovation through the evaluation of new technologies, such as active noise control and emission control. Also, supported warranty reviews with customer.
Program Manufacturing Leader
Faurecia Clean Mobility
Columbus, IN
04.2017 - 11.2020
- Utilized Lean manufacturing principles to improve profit margins (~15%) by designing, developing and Industrializing new production lines and negotiating competitive vendor contracts for several manufacturing plants across the US, Mexico & Canada
- Lead all aspects of manufacturing process from acquisition to serial production, including process design (IDW, PFA), Tooling Design (DFM&A), CAPEX & Tooling budget and procurement, industrialization timing, capacity planning & analysis and achieving performance targets which improved customer satisfaction by finding creative solutions to problems.
- Lead development, validation and release of complete production system to shopfloor using production methodologies, including process flow charts, SWC, PFMEA, DFMEA, Gap Analysis and Control plans.
- Successfully completed multiple QRCI (Quick response continuous improvement) projects to solve most engineering and manufacturing challenges in the program & derive new technical solutions.
- Delivered successful launch of various GM (T1XX - Truck and SUV) and Ford (C482 - Explorer) programs to customer locations.
Mechanical Design Engineer
Tidi Products LLc
Fenton, MI
01.2017 - 04.2017
- Checked design compliance with product specifications and standards requirements.
- Created new EBOM's and CAD designs through internal product management portal
- Worked with domestic and international suppliers to fabricate both prototype and production parts.
- Performed tolerance stack up analysis to validate part dimensions and correct assembly.
Manufacturing Engineer
Maruti Suzuki
Gurgaon, Haryana, India
05.2011 - 11.2014
- Managed capital equipment (RFQ's, Quote Evaluation, Selection, APQP's, Run off's, Implementation) & Evaluated production capacities
- Lead procurement of spares, maintenance and repair on Die Casting machines and tools.
- Delivered proven technical support in collaboration with Quality, Design, Logistics, Program Management & suppliers to resolve major quality issues and implementation of various Kaizen projects.
- Lead PPAP deliverables for any new program launch or engineering changes by providing Manufacturing documentation.
Education
Master of Science - Industrial Engineering
The University of Texas At Arlington
Arlington, TX01.2016
Bachelor of Science - Automotive Design Engineering
University of Petroleum & Energy Studies
Dehradun, India01.2011
Skills
- CAD/CAM Software: CATIA, SolidWorks, NX
- PLM Software: Siemens Teamcenter
- Simulation Tools: GT-Power
- Data Analysis & Statistical Tools: Minitab, Excel
- Quality Assurance & Testing
- Platform Management & Integration
- Lean Manufacturing Principles
- Continuous Improvement & Innovation
Certification
- Six Sigma Green Belt, ASQ License No. 15295
- Affiliated with Society of Automotive Engineers (SAE)
Timeline
Program Manager
Faurecia Clean Mobility
09.2025 - Current
Lead Engineer
Faurecia Clean Mobility
12.2020 - 08.2025
Program Manufacturing Leader
Faurecia Clean Mobility
04.2017 - 11.2020
Mechanical Design Engineer
Tidi Products LLc
01.2017 - 04.2017
Manufacturing Engineer
Maruti Suzuki
05.2011 - 11.2014
Bachelor of Science - Automotive Design Engineering
University of Petroleum & Energy Studies
Master of Science - Industrial Engineering
The University of Texas At Arlington