Dipl.-Ing. Sergey Kasatov

Design Release Engineer | PSA Trnava, Slovakia • Led part design and engineering release activities for over 100 Body-in-White (BIW) parts, focusing on upper body and closures for the OV24 and CC24 projects. • Provided comprehensive launch support from the Body Engineering site, ensuring smooth integration and alignment with production specifications.

Quality New Model Launch Engineer | Opel Werk Eisenach, Germany • Conducted incoming part quality inspections and internal quality audits for the Opel Grandland X facelift, ensuring components met stringent quality standards. • Supported the launch from the Internal Quality team, driving quality assurance measures to facilitate a seamless production start.

Manufacturing Engineer | Opel Werk Rüsselsheim, Germany • Managed the integration of the new-generation Opel Astra into the existing General Assembly production line, optimizing processes to enhance production flow.

Internal Logistics Specialist for GA | Opel Werk Eisenach, Germany • Integrated additional BOM materials into the existing supply chain processes for the Opel Grandland X (PHEV) production line. • Redesigned Supermarket interim storage and developed E-Kanban routes to streamline internal logistics and improve material handling efficiency.

Manufacturing Engineer | PSA Trnava, Slovakia • Optimized the General Assembly production line for the Peugeot 208/e208 electric vehicle, enhancing efficiency of manipulators in the Battery Shop and planning Automated Guided Vehicle (AGV) lines. • Utilized PSA tools and processes (SP3, SAVANA, CdC, E-Consultation, MERLIN, SACHA, RIBE PR, PV) to improve production standards and streamline manufacturing engineering operations.

• Provided technical direction to local suppliers in the manufacturing of exterior and interior parts for Ford Sollers Holding Russia, ensuring adherence to high-quality and regulatory standards. • Coordinated projects for local production of metal-stamped parts, overseeing both serial and after-sales components to ensure production readiness and quality compliance.

• Coordinated technical support for Body Exterior components of GM products in the Russian market, ensuring compatibility and quality for Chevrolet, Opel, and Cadillac models. • Facilitated the integration of engineering changes and localization of BIW/exterior parts, aligning with GM’s technical requirements to support smooth transitions in production. • Managed change processes for localized parts, working closely with suppliers to implement modifications in accordance with technical and quality standards

• Managed project coordination for Body Exterior and Chassis suppliers, conducting assessments to ensure quality targets were met for the Ford Kuga. • Collaborated with the customer service division to design optimal repair methods for the Body-in-White rocker area on the Ford C-Max, integrating new joining techniques for enhanced repair efficiency. • Conducted quality assessments and provided feedback to suppliers, contributing to continuous improvement in supplier performance.

• Utilized CATIA and ANSYS to simulate and calculate the mechanical and thermal behavior of an injection-molded pressure distributor used in the dynamic seat of the Daimler S-Class, ensuring design accuracy and performance. • Optimized the injection molding process by investigating and simulating various cooling techniques, leading to improved efficiency and process reliability.

• Coordinated localization projects for “Chassis Parts” and “Body/Stamping Parts” for major clients, including FIAT and ISUZU, ensuring that local production met technical and quality standards. • Conducted technical audits across 40 local suppliers in the Russia region, evaluating manufacturing capabilities, quality controls, and production management systems to enhance supplier reliability. • Collaborated closely with suppliers to implement best practices, contributing to robust supplier development.

• Enhanced production processes for oil pump components by improving quality, productivity, and efficiency, leading to measurable cost savings in manufacturing. • Designed control data for CNC milling machines, optimizing operations and increasing precision in production workflows. • Conducted market research on materials, tools, and machinery, securing competitive pricing that significantly reduced production costs.

• Optimized production processes for aircraft engine and mini power plant components, enhancing quality, productivity, and efficiency while achieving cost savings in manufacturing. • Supported technical improvements through detailed process modifications that aligned with quality and performance standards in the aerospace industry. • Contributed to cross-functional team efforts in implementing process enhancements, leveraging skills in AutoCAD and quality control for successful outcomes.

Metal cutting production planning. Parts design.