Sudhir Kulkarni

Mobile: +91-9916835003
E-Mail: sukudec17@gmail.com

Key Expertise

Competent Manufacturing Engineer with 8+ years of experience in Lean Manufacturing, Value

Engineering and Compliance documentation. Mechanical Engineer turned Engineering services
professional with hands on assembly processes, composite molding, sheet metal and machine part
fabrication. Has extensive experience in process mapping, Should Costing and cost analytics.
Successfully transformed problem statement to solutions for multiple OEM’s.

Experience Summary

 Possess strong knowledge & shop floor experience on autoclave composite molding;
manufactured 7000+ serialized composite jet engine components which include Acoustic Panels,
Attrition liners, Cowlings & Fairings.

 Gained knowledge on aircraft structural assembly. Hands on experience include Fuselage cockpit
Assy, wings substructure Assy, Radome Assy, PAX Door Assy, NLG Door Assy, Mission Cabinet
Assy, Power cabinet Assy, Flap-track Beam Assy and Slat Assy.

 Acquired knowledge on metallic manufacturing which includes sheet metal and machined
components. Well versed with casting, forging, stamping, machining, heat treatment,
Nondestructive inspection, surface preparation and painting processes. Manufactured 100+
primary load bearing components such as Frame, Stringer, Spar and Bulkhead.

 Performed should costing of 200+ components and sub-assemblies using comprehensive and
standardized estimation process. Marked consolidated saving of US$10M.

 Co-Led 4 value engineering projects and successfully delivered projects within Scope, Cost and
Schedule. Tracked consolidated savings of US$1M.

 Conducted value stream mapping & value analysis on 3 categories of components with emphasis
on reducing cycle time, cost and increasing productivity. Achieved US$180K savings in 2014.

 Performed Vendor selection, development and approval process through the feasibility and
capability analysis.

 Proposed alternate materials and manufactured 300+ components which reduced expenses by
30%.

 Proven track record in addressing production issues, writing rework/salvage procedures and
complying with regulatory/standard requirements such as ISO 9001, AS 9100, NADCAP, EASA Part
21, Part-145.

 Proficient in methodologies of Route Cause Analysis (RCA), Failure Mode Effect Analysis (FMEA),
Define Measure Analyze Implement Control (DMAIC), Six Sigma, Kaizen.

Skills Summary
Domain Aerospace Composite and Metallic manufacturing, Structural Assembly
Lean Manufacturing, Technical Writing, Process Improvement, Cost
Skills
Optimization, Value Stream Mapping, Vendor Development, Documentation
Catia V5, Catia Fibersim, Creo 2.0 & 3.0, Enovia, 3DVia Composer, AutoCAD,
Software
SAP

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Sudhir Kulkarni
Mobile: +91-9916835003
E-Mail: sukudec17@gmail.com

Project Details

Neviton Softech Pvt Ltd, Bengaluru

Project 1:
Should Costing for Machined/Sheet Metal Duration 1 year 6 Months
Project Name Components Team Size 9
(From July-2017 to Till Date)
Description Should Costing support onsite/offshore model
Role: Tech lead
Contribution:
 Performed product cost reduction in a target-oriented manner
through should cost & cost analytics for 300+ items.
 Leading product strategy (Design & Cost) for NPI and legacy products
through competitive benchmarking, technology landscaping
& Should cost with focus on Mechanical parts/assemblies.
 Recommended improvements, Optimized processes and
Role & Contribution identified cost opportunities, advised product development engineers on
economic alternatives for their design and suggested trade-offs.
 Hands on working with major composite skins such as Fuselage, Wings,
Nosecone, Tailcone, Vertical Stabilizer, Horizontal Stabilizer.
 Led process optimization & stabilization though brainstorming & value
stream mapping methodologies. Achieved US$0.5M cost saving to
customer.
 Hands-on cost estimation/reduction techniques (DFA, DFM), tools (aPriori,
DFMEA, etc.) & processes for mechanical assemblies.
Tools Catia V5, aPriori, Seer, UG-NX8

Tech Mahindra, Bengaluru

Project 2:
Manufacturing support to Aircraft OEM Duration 2 years 6 Month
Project Name
(From Dec-2014 to June-2017) Team Size 5
Description Manufacturing support onsite/offshore model
Current Role: Sr. Manufacturing Engineer
Contribution:
 Translated engineering requirements to shop floor document to ease of
understanding and interpretation.
 Developed work instruction standards which is referred to create
individual process sheets. Saved documentation time by 50%.
 Identified 5 potential opportunities, performed value analysis and
Role & Contribution presented ideas to customer, which realized 3 value engineering projects
of worth US$5M.
 Co-led implementation of automated KPI reporting to customer. Improved
Customer Satisfaction (CSAT) from 3 to 4.5.
 Explored opportunities of automation in shop floor and piloted 2 projects,
able to materialize 1 project of budget US$10M.
 Successfully carried out capability study on manufacturability and
suggested design changes by analyzing engineering drawings.
Tools Catia V5, Creo 2.0 & 3.0, Enovia, 3DVia Composer, SAP and File-Zilla

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Sudhir Kulkarni
Mobile: +91-9916835003
E-Mail: sukudec17@gmail.com
Project 3:
Interior Layout Design for Aircraft OEM Duration 5 months
Project Name
(From July-2014 to Nov-2014) Team Size 6
Description Layout Design of interior Monuments
Role: Design Engineer
Contribution:
 Successfully designed & developed 50+ layout drawings in compliance
with VOC & Customer Standards.
 Achieved design improvements and avoided potential design & usability
Role & Contribution
hazards based on monument compliant history analysis.
 Successfully reduced 20% of weight of nonstructural components such as
racks, storage bin by proposing alternate materials.
 Led concept generation & selection activities though brainstorming &
selection technique.
Tools Catia V5, Creo 2.0 & 3.0, Solidworks, AutoCAD, Enovia

Project 4:
Manufacturing support to Aircraft OEM Duration 1 year 11 Months
Project Name
(From Aug-2012 to June-2014) Team Size 15
Description Manufacturing support onsite/offshore model
Role: Engineer
Contribution:
 Successfully Developed 200+ composite work instruction achieving 99%
First Time right (FTR) compliance with customer standards.
 Hands on working with major composite skins such as Fuselage, Wings,
Nosecone, Tailcone, Vertical Stabilizer, Horizontal Stabilizer.
 Led process optimization & stabilization though brainstorming & value
stream mapping methodologies. Achieved US$0.5M cost saving to
customer.
 Developed automated traceability sheet creation, which saved 12 Minutes
Role & Contribution
per file, saving 40 Man Hours per month.
 Bracket common customer inputs and restructured to use as template,
which increased productivity by 20%.
 Design and developed 3D models using CATIA V5 Fibersim to assist in
fabrication. This has widened scope of work, adding new revenue stream
to organization.
 Developed 100+ ply cutting NC programs and 50+ laser projection
programs for Lerjet-85 Aircraft.
 Created Mylar templates to use in shop floor for positioning, drilling,
masking etc.
Catia V5, Catia Fibersim, Creo 2.0 & 3.0, Enovia, 3DVia Composer, SAP, Vericut
Tools
and MACPAC/CAPPD

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Sudhir Kulkarni
Mobile: +91-9916835003
E-Mail: sukudec17@gmail.com
Tata Advanced Materials Limited, Bengaluru

Project 5:
Composite Component Manufacturing Duration 2 Years
Project Name
(From June-2010 to July-2012) Team Size 5
Description Build to Print Composite manufacturing for Jet Engine OEM
Role: Methods Engineer
Contribution:
 Authorized and aligned organization to manufacture jet engine components
by compliance to customer standards.
 Created Standard operating procedures (SOP) for critical processes such as
Reticulation, Pressure or Pressure less curing, Surface Preparation, Epoxy
Painting and Identification.
 Created Bill of materials, Work Instructions, Route cards for 100+
components emphasis on manufacturability, process improvement, cost
Role & Contribution
optimization, cycle time and effective equipment utilization.
 Successful on localization of ancillary materials which helped organization to
reduce cost up to 30% without affecting component Fit, Form and Function.
 Led and implemented lean manufacturing methodologies with emphasis
production stabilization, Achieving First Time Right and on time Delivery.
 Proposed 10 salvage procedures to customer for common defects and
reworked 50+ components with approval. Saved US$0.4M to organization.
 Led Kaizen activities and improved utilization of work space by 30%.
 Compliance with standards such as ISO9001, AS9100 and NADCAP.
Tools Catia V5, Creo 2.0 & 3.0, AutoCAD & SAP

Educational Qualification & Certifications

Aerospace MBA from Toulouse Business School, France in Collaboration with Indian
Master’s Degree
Institute of Management, Bengaluru
Bachelor of
Mechanical Engineering from VTU Belgaum, India 2010 batch
Technology
ASQ Certified for Lean Six Sigma-Green Belt (LSS-GB) Practitioner, masters in
DMAIC procedure.
Trainings
Certified for part time course on General Management Programme for Aerospace
and Aviation Executives (GMAE) at Indian Institute of Management, Bengaluru

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