---
title: "Suraj D - Lead Engineer in Bengaluru | Tal"
description: "Meet Suraj D, Aerospace Manufacturing Engineer | BITS Pilani | ex-Bosch | ex-Toyota based in Bengaluru. AI stack includes gemini, meta, and openai."
image: "https://tal.club/meet/suraj-d/share-image"
---

# Suraj D on Tal

## 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

[View the original profile](https://tal.club/meet/suraj-d)

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