Playing Flute
SACHIN GAYAKWAD
LEAD ENGINEER: NPD 11+ Years Exp | System Integrator | Program Manager | PMP | Opex Black Belt | 6 Sigma GB | Structural SME | MTech | Cooking Appliances Design | 2+ Patents | CSEP
Pune
Summary
Dedicated and results-driven Product Design and Development Lead with over 11+ years of experience, consistently exceeding expectations in defining product quality and fostering customer-centric design approaches. Proven expertise in system integration, program management, Structural lead, and innovative solution development. Subject Matter Expert in project management, Six Sigma methodologies, system engineering, Design for Quality, Design for Excellence (DFX)
Overview
11
11
years of professional experience
9
9
years of post-secondary education
3
3
Certifications
4
4
Languages
Work History
System Integrator / Program Manager
Whirlpool Corporation
1 2017 - Current
- Skillfully coordinated the technical integration of diverse systems across multiple projects.
- Specialized in designing solutions tailored to meet exact customer requirements.
- Converted all Voice of Customer (VOC) inputs to Voice of Engineer (VOE), ensuring capture of all regional regulatory and code requirements.
- Expertly launched products through strategic finished product sourcing.
- Collaborated closely with suppliers, educating them about acceptance criteria.
- Traveled onsite to enhance collaboration with suppliers.
- Excelled in managing communication with different stakeholders according to stakeholder grids and communication plans.
- Communicated globally with stakeholders on a weekly and monthly basis.
- Seamlessly integrated complex systems such as hoods, cooktops, built-in ovens, FSR, warming drawers, and MWOs across multiple projects as a program manager.
- Provided effective engineering solutions through critical thinking and application of methodologies like MSE, COV, DOE, and Noise strategy in real-world scenarios.
- Implemented all regulations and code requirements for products in Asia & NAR regions, including application submissions to local authorities for UL, COC, CB, and IEC.
- Leveraged RQM, DNG, and MBSE tools to define requirements, create product maps and block diagrams, understand failure modes, and ensure system functioning post-integration.
- Skilled in value stream mapping to reduce waste and enhance turnaround times using continuous improvement (CI) methodologies.
- Met PPAP and GPA requirements across all projects.
- Infused DFx (DFA, DFM, DFR, DFS, DFSS) methodologies in design and coached/mentored project engineers to resolve design issues.
- Provided technical solutions and interacted with global stakeholders from NAR, EMEA, and ASIA, mitigating risks, issues, and knowledge gaps within project schedules.
- Managed cross-functional teams for successful project completion within deadlines and budgets.
- Managed multiple strategic projects with numerous sub-projects or workstreams.
Sr. Design and Development Engineer
Elcom International
06.2014 - 12.2016
- Highly effective in providing engineering solutions through critical thinking and practical application of methodologies such as MSE, COV, DOE, and Noise strategy in real-world scenarios
- Hands-on experience on different Plastic and Sheet metal design parts ensuring optimal cost and maximum efficiency
- Preparation of tools, jigs, and fixtures to carry out a smooth production process with maximum productivity
- Ensuring Product meets PPAP & Audit requirements.
- Evaluate and recommend the developed concepts in terms of engineering, and manufacturing and suggest the best concepts, priority of selection, and another trade-off if necessary
- Deploy Six Sigma initiatives to ensure engineering quality and continuous improvement across the portfolio
- Proficient in tolerance stack-up analysis using both 1D linear and 3D CETOL methods
- Perform the tasks of analyzing technical drawings and schematics to develop the product according to it and then assisting in the development process.
- Transformed 2D drawings into 3D solid models and drafted them according to client specifications, either as Product models or Customer view models, utilizing Pro-E, Solid Works
Design Engineer
IEW Cranes
06.2013 - 05.2014
- Highly effective in providing engineering solutions through critical thinking and practical application of methodologies such as MSE, COV, DOE, and Noise strategy in real-world scenarios
- Hands-on experience on different Platic and Sheet metal design parts ensuring optimal cost and maximum efficiency
- Rapid prototyping of models for designed products & Validation
- Preparation of tools, jigs, and fixtures to carry out a smooth production process with maximum productivity
- Responsible for the first launch of production
- Ensuring Product meets PPAP & Audit requirements
- Evaluate and recommend the developed concepts in terms of engineering, and manufacturing and suggest the best concepts, priority of selection, and another trade-off if necessary
- Deploy Six Sigma initiatives to ensure engineering quality and continuous improvement across the portfolio
- Proficient in tolerance stack-up analysis using both 1D linear and 3D CETOL methods
- Perform the tasks of analyzing technical drawings and schematics to develop the product according to it and then assisting in the development process
- Utilized CAD software such as Pro/E-Creo to generate manufacturing drawings
- Preparation of BOM and Costing for the new requirements
- Transformed 2D drawings into 3D solid models and drafted them according to client specifications, either as Product models or Customer view models, utilizing Pro-E, Solid Works
- Acquired an understanding of plastics and manufacturing processes during project engagements.
Education
Master's In Design Engg -
BITS PILANI
01.2021 - 04.2023
B.E Mechanical Engineering - undefined
Visvesvaraya Technological University, Belgaum
01.2010 - 04.2013
Diploma In Automobile Engineering - undefined
GOVT Polytechnic, Belgaum.(DTE Board)
01.2007 - 04.2010
Skills
Program Management & PMP Certified
Certification
PMP - Project Management Professional
Accomplishments
- 2 Patent Granted. + 3 Patent In progress
- Product delivery 22% Faster time to Market by following continuous improvement methodology.
- 0.9% GSIR reduction on Quality projects results in $3M savings for the NAR region.
Projects
Minerva Built-In Oven, FSR for NAR, Michigan, US (Onsite), Subsystem Module Lead for built-in oven & FSR structural design. Managed complete design accountability, ensuring functional requirements were met. Resolved technical risks using FMEA, DVP, stack-ups, DFX, and various concepts to meet stakeholder expectations. Contributed to achieving NAR product leadership. Demonstrated $2M of Cost avoidance with complexity reduction from 20 to 5 Assemblies. +2 Patents.
Cooking Asia Drop-In Program, Asia Region, Pune, As a System Integrator, ensuring subsystem functionality with different teams. Launched 30+ products in Asia Pacific, achieving a $10M DCM impact and reducing time to market by 22%. Performed process mapping for Elica products, eliminating waste, and promoting knowledge development. 600+ SKU Validation, PS9 Lab & adhering QCO's.
Structural Capability Roadmap, Developed a systematic roadmap for the engineering team in structural design with local test facilities. Tailored validation techniques using real field data, introducing 8 test methods, modifying 3 standards, and achieving a 0.5% SIR reduction.
Interests
Playing Video Games
Traveling & DIY
Cooking
Software
Minitab
Creo
Cetol
DFM Pro
SAP
Smart Sheet
Lucid Chart
Solid works
Timeline
PMP - Project Management Professional
11-2026
Master's In Design Engg -
BITS PILANI
01.2021 - 04.2023
Sr. Design and Development Engineer
Elcom International
06.2014 - 12.2016
Design Engineer
IEW Cranes
06.2013 - 05.2014
B.E Mechanical Engineering - undefined
Visvesvaraya Technological University, Belgaum
01.2010 - 04.2013
Diploma In Automobile Engineering - undefined
GOVT Polytechnic, Belgaum.(DTE Board)
01.2007 - 04.2010
System Integrator / Program Manager
Whirlpool Corporation
1 2017 - Current
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