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Suraj D

Aerospace Manufacturing Engineer | BITS Pilani | ex-Bosch | ex-Toyota

Bengaluru

13+ years of work experience

Quest Global Engineering Services (Client Collins Aerospace)
Mar 20233 yrs 6 mosPresent

• Active participation in raising Safety concerns, preparing JHA. • Led manufacturing engineering and production operations for aerospace components in a high-precision environment. • Conducted production line capacity analysis, eliminating bottlenecks and improving throughput by 24% using Time & Motion studies and cycle time optimization. • Review Process Design, setting of process and establishment of products for commercial, aerospace components. • Resolved recurring quality issues using CPS methodologies, improving defect-free rate from 83% to 98%. • Collaborated with cross-functional teams (engineering, quality, supply chain) to align production schedules with business goals, improving on-time delivery rates by 24%. • Implementation of MES in Process and Training MES systems used in aerospace to technicians. • Implemented process improvements that increased production efficiency by 15%. • Enhanced first-pass yield (FPY) by 90%, reducing rework and scrap in assemblies. • Mentored junior engineers and production personnel, improving adherence to standard operating procedures (SOPs) and safety compliance. • Prepare and update PFD, PFMEA, SOP, and relevant documents to ensure sustained corrective actions. • Manage Routing, BOM’s of products through SAP. • Ensure Change management process of products and processes. • Involved in comprehensive audit documentation with AS9100 standards and client-specific requirements for major aerospace OEMs including Safran, Boeing, Airbus, Bombardier, Embraer, Diehl, FACC, Gulfstream, and Pilatus.
Robert Bosch Automotive Electronics
Jan 20194 yrs 3 mosMar 2023

Bengaluru, Karnataka, India

• Preparation of standards (Work instruction, Handling instruction, lesson learnt etc.) • Led manufacturing operations and engineering improvements for a 100+ workforce facility. • Improved capacity utilization from 82% to 95% through engineeringdriven optimization. • Led daily SQPDC reviews to track performance, enforce shop floor discipline, and maintain production visibility, Improving accountability and operational transparency. • Applied Value Stream Mapping (VSM) to analyze material and information flows, reducing lead times from 7 days to 4 days (43% improvement) and streamlining processes across multiple production lines. • Led accurate operation cost planning during New Product Development by strategically procuring tools, fixtures and equipment, staying within allocated budget. • Implemented Total Productive Maintenance (TPM) by standardizing equipment care best practices, achieving zero accidents for 24 consecutive months. • Improving defect‑free rate from 85% to 98% and cutting unplanned downtime from 21% to 12% (40% reduction). • Reduced setup and changeover time using SMED, cutting average duration from 5 hours to 75 minutes (75% reduction) while eliminating trial runs and material waste. • Established a Supermarket system for improving On‑Time Delivery (OTD) from 89% to 98. • Demonstrated strong problem‑solving skills by identifying issues, analyzing root causes, and implementing effective solutions to sustain operational performance. • Identified major losses in production and successfully improved Overall Equipment Effectiveness (OEE) by enhancing equipment availability
Toyotetsu india auto parts
Aug 20153 yrs 6 mosJan 2019

• Supported in line setup activities for new model car project for Layout designing, modifying, testing manufacturing methods, equipment. • Handling 20+ operators in Innova/Fortuner project line. • Supported new machine installations and assembly projects as part of NPD. • Collaborated with CFT teams to resolve quality issues, reducing defects by 28%. • Improved a KANBAN pull system to boost operational efficiency and eliminate key waste. • Ensured the implementation of the Milk Run process in Supply Chain Management to reduce inventory levels and optimize delivery efficiency. • Led the implementation of the QSB framework, conducting Layered Audits, Control Plan Audits, Dock Audits, Tool Audits, and Store Audits. • Ensured ISO 9001:2015, EHS, and OHSAS audit compliance. • Risk management activities for smooth running of production during IR issues.
Toyota Kirloskar Motor
Oct 20131 yr 11 mosAug 2015

Bangalure

Suraj’s AI Stack

gemini
gemini
meta
meta
openai
openai
ChatGPT
ChatGPT

Education

Birla Institute of Technology and Science, Pilani

Bachelor of Engineering - B.E

Birla Institute of Technology and Science, Pilani

20213 yrs2024

Diploma, Mechanical Engineering

Reedy jana sagha polytechnic

20103 yrs2013

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Headline

Aerospace Manufacturing Engineer | BITS Pilani | ex-Bosch | ex-Toyota

About

Lead Engineer with 12 years of experience in manufacturing domain.

Location

Bengaluru

AI stack

gemini

meta

openai

ChatGPT

Work experience

Lead Engineer at Quest Global Engineering Services (Client Collins Aerospace), Mar 2023 - Present · 3 yrs 6 mos, • Active participation in raising Safety concerns, preparing JHA. • Led manufacturing engineering and production operations for aerospace components in a high-precision environment. • Conducted production line capacity analysis, eliminating bottlenecks and improving throughput by 24% using Time & Motion studies and cycle time optimization. • Review Process Design, setting of process and establishment of products for commercial, aerospace components. • Resolved recurring quality issues using CPS methodologies, improving defect-free rate from 83% to 98%. • Collaborated with cross-functional teams (engineering, quality, supply chain) to align production schedules with business goals, improving on-time delivery rates by 24%. • Implementation of MES in Process and Training MES systems used in aerospace to technicians. • Implemented process improvements that increased production efficiency by 15%. • Enhanced first-pass yield (FPY) by 90%, reducing rework and scrap in assemblies. • Mentored junior engineers and production personnel, improving adherence to standard operating procedures (SOPs) and safety compliance. • Prepare and update PFD, PFMEA, SOP, and relevant documents to ensure sustained corrective actions. • Manage Routing, BOM’s of products through SAP. • Ensure Change management process of products and processes. • Involved in comprehensive audit documentation with AS9100 standards and client-specific requirements for major aerospace OEMs including Safran, Boeing, Airbus, Bombardier, Embraer, Diehl, FACC, Gulfstream, and Pilatus.

Engineer at Robert Bosch Automotive Electronics, Jan 2019 - Mar 2023 · 4 yrs 3 mos, Bengaluru, Karnataka, India, • Preparation of standards (Work instruction, Handling instruction, lesson learnt etc.) • Led manufacturing operations and engineering improvements for a 100+ workforce facility. • Improved capacity utilization from 82% to 95% through engineeringdriven optimization. • Led daily SQPDC reviews to track performance, enforce shop floor discipline, and maintain production visibility, Improving accountability and operational transparency. • Applied Value Stream Mapping (VSM) to analyze material and information flows, reducing lead times from 7 days to 4 days (43% improvement) and streamlining processes across multiple production lines. • Led accurate operation cost planning during New Product Development by strategically procuring tools, fixtures and equipment, staying within allocated budget. • Implemented Total Productive Maintenance (TPM) by standardizing equipment care best practices, achieving zero accidents for 24 consecutive months. • Improving defect‑free rate from 85% to 98% and cutting unplanned downtime from 21% to 12% (40% reduction). • Reduced setup and changeover time using SMED, cutting average duration from 5 hours to 75 minutes (75% reduction) while eliminating trial runs and material waste. • Established a Supermarket system for improving On‑Time Delivery (OTD) from 89% to 98. • Demonstrated strong problem‑solving skills by identifying issues, analyzing root causes, and implementing effective solutions to sustain operational performance. • Identified major losses in production and successfully improved Overall Equipment Effectiveness (OEE) by enhancing equipment availability

Technical Lead at Toyotetsu india auto parts, Aug 2015 - Jan 2019 · 3 yrs 6 mos, • Supported in line setup activities for new model car project for Layout designing, modifying, testing manufacturing methods, equipment. • Handling 20+ operators in Innova/Fortuner project line. • Supported new machine installations and assembly projects as part of NPD. • Collaborated with CFT teams to resolve quality issues, reducing defects by 28%. • Improved a KANBAN pull system to boost operational efficiency and eliminate key waste. • Ensured the implementation of the Milk Run process in Supply Chain Management to reduce inventory levels and optimize delivery efficiency. • Led the implementation of the QSB framework, conducting Layered Audits, Control Plan Audits, Dock Audits, Tool Audits, and Store Audits. • Ensured ISO 9001:2015, EHS, and OHSAS audit compliance. • Risk management activities for smooth running of production during IR issues.

Trainee at Toyota Kirloskar Motor, Oct 2013 - Aug 2015 · 1 yr 11 mos, Bangalure

Education

Bachelor of Engineering - B.E, Birla Institute of Technology and Science, Pilani

Diploma, Mechanical Engineering, Reedy jana sagha polytechnic