SUJOY PAL

 Managing and responsible for all Should Cost / DtV / DtC / Competitive Benchmarking.  Developing a complete cost engineering solution with value Engineering.  Driving a global team of Value and Cost.  Cost target setting according to feature, market and Customer requirement.  Maintaining the complete machine-level cost gap analysis and maintaining product cost goals.  Facilitating cross functional Supplier workshops/ knowledge sharing session new cost saving value added ideas generation.

 Should Cost / Global Sourcing / Design to cost / LCC or BCC Localization / VAVE .  RFQ/RFI of business proposal.  Supplier selection, database creation, alternative materials & new supplier suggestions.  All costing & supplier negotiation of interior, exterior, plastic, Casting, Forging, Welded / fabricated, Machined Block, Wiring harness, Switch, lamps, Motors, alternator etc.  Experience in Cost estimation tool as Costimator 3DX, DFMA - Boothroyd, aPriori, Siemens TCPCM, SEER-Galorath etc.

 Should Cost, Manufacturing Process Planning, Design and Manufacturing Support .  Detail cost estimation of complex light / heavy fabricated / structural / welded assemblies, machined, plastics, castings, forgings components.  Machine Hr rate calculation, Zero & Activity based cost estimation, manufacturing routing, assembly costs and target costing.  Customer communication, project plan, project schedule, resource plan, RFI, RFQ, profit margins, project invoicing, project budget & project delivery.

 Worked in Engineering Services Division.  Design & Manufacturing Support.  Supplier Collaboration, Supplier Audit & Development Plans, Evaluation of Supplier documents in Automotive & Heavy Engineering domain.

• Testing & support services to Machine Shop,Tool Room, heat treatment, purchase, inspection, vendor quality management cell. • Quality Assurance Plan, Vendor development, evaluation & source approval. • Failure analysis, root cause analysis, CAPA, 8D format. • Trouble shooting for various line & field complaints. • Working with structural steels, forgings, casting, and plastics. • BS, IS, DIN, JIS, DBL & MAN Standard. • TS 16949 standard, 7 QC tools, TQM, SPC, FMEA, APQP, PPAP, SOP, MSA etc.

 Welding Consumables Design, Development & applications.  Welding processes and parameters of SMAW, SAW, TIG, MIG, FCAW etc.  Weldability test, IGC test, Mechanical, Metallography, XRF, Spectro Analysis, NACE, NDT etc.  QMS, EMS, Product Quality Audit, Quality cost, Quality conformity report.  3rd Party inspection from LRS, ABS, IRS, DNV, BV, IBR, NPCIL, RDSO.  Vendor Audit and alternate Source approval.  Handling customer complaints and monitoring corrective/preventive actions.

 Physical & Chemical testing of different grades Cast Iron alloys.  Dimensional examinations of patterns & cast products, Chemical & Instrumental analysis.  Inspections about various defects , design of gating systems for different type of castings and audit & inspections in liaison with different external agencies like KPMG , Sigma – USA, Rites, RDSO etc  Furnace charging analysis with different grades of pig iron & other raw materials.  Metallography &Statistical Process Control.

Materials, Logistics and Supply Chain Management

Light Metals Alloys and Composite, Magnesium alloy and composite, Material Characterization, Creep, wear and corrosion study.

Manufacturing Processes and Technology, Powder Metallurgy and Welding.