Sergey Kasatov

Owned launch readiness and engineering change management for BIW and Closures during ramp-up. • Coordinated OEM, plant and supplier stakeholders across development and launch phases. • Managed ECR/ECO implementation and engineering change tracking. • Built and maintained weekly KPI and quality tracking to prioritize critical issues. • Used structured issue analysis and follow-up to reduce closure time and rework. • Supported cost savings through data-driven prioritization of launch topics.

Led supplier-facing execution for Body Exterior & Interior at Ford, focusing on launch readiness, KPIs and coordination. • Led a team of 3 engineers across supplier and plant interfaces. • Supported 7 vehicle launches through issue tracking and follow-up. • Built weekly KPI reporting to monitor SOP readiness and priorities. • Managed supplier quality/launch topics to improve closure speed and production stability. • Delivered cost savings through standardization, localization and component improvements.

Managed BIW localization and SOP readiness activities, using structured tracking and reporting to align suppliers and support approvals. • Localized 25 BIW stamped parts with local suppliers, delivering €75k cost savings. • Built localization tracking and weekly reporting to support decisions. • Coordinated SOP readiness for 2 vehicle programs across 3 suppliers. • Supported BIW and body exterior components across multiple GM brands. • Worked with cross-functional teams to resolve open issues.

Supported prototype-build readiness and supplier coordination for Ford Kuga exterior and chassis components. • Managed readiness tracking for 45 components and supplier deliverables. • Maintained structured tracking for part status, compliance checks and open issues. • Supported timely escalation and closure ahead of prototype build events. • Contributed to 100% prototype-build readiness within assigned scope. • Documented UHSS body repair methods, reducing estimated repair cost by ~15%.

Performed thermo-mechanical simulation and optimization for injection-molded pressure distributors, supporting process improvements. • Ran CAE simulations in CATIA and ANSYS for cooling optimization. • Reduced cooling time by 35% through optimized cooling concepts. • Documented methods and test results for 15 parts. • Analyzed alternative cooling techniques and summarized implementation recommendations.

Owned supplier quality and launch readiness for chassis and body parts, driving audits, PPAP/APQP and corrective actions. • Audited 20+ suppliers and led corrective-action follow-up. • Led PPAP/APQP for 35 parts to support launch readiness. • Supported 3 vehicle launches in FIAT and ISUZU programs. • Closed 8 critical pre-SOP issues through root-cause analysis. • Coordinated cross-functional teams to ensure milestone compliance.

Supported machining process optimization for oil pump components, improving stability, quality and throughput through CNC programming and shopfloor implementation. • Developed and validated 8 CNC programs for oil pump components. • Improved machining steps, reducing manufacturing costs by ~15%. • Achieved target quality 2 weeks earlier by stabilizing key process parameters. • Coordinated with production and quality teams to standardize work instructions.

Supported manufacturing and process improvement work for aircraft engine and mini power plant components. • Updated 15 technical drawings (AutoCAD) and aligned documentation with production and quality requirements. • Adjusted 4 work instructions to support standardized execution. • Supported quality control and testing for 3 parts with production and quality teams. • Improved cycle time by ~12% by optimizing part storage and material flow.

• Hands-on training in data analytics using Python, SQL, Pandas and Tableau. • Worked with real datasets to perform data cleaning, analysis and visualization. • Built dashboards and reports to support data-driven decision-making. • Applied statistics and introductory machine learning methods for pattern detection and forecasting.

• Focus areas: Mathematical Modelling & Simulation, Vehicle Dynamics, Automotive Electronics. • Research project: Optimized repair methods for BIW rocker area (Ford C-Max). • Practical experience with CATIA V5, thermal analysis and cross-functional collaboration. • Gained strong understanding of automotive systems, applied research and international teamwork. • Completed full coursework towards MEng in International Automotive Engineering.

• Focus areas: Part Design, Process Engineering, Material Science. • Diploma thesis: Design of a mechanical workshop for pump component production in the oil and gas industry. • Gained practical experience in CNC programming and industrial process development. • Graduated with honors.