Sunil Dipke

1. BIW Development & Tooling Execution 2. Vendor Coordination & Tool Maturation 3. Welding Fixture Development 4. Project Management & Technical Review 5. Cost Estimation & Business Acquisition

• Executed full-cycle BIW sheet metal part development, from styling to PPAP including formability analysis using AutoForm.
• Designed progressive, draw, and trim dies for side panels, underbody, closures, and pillars for 2W/3W/4W EV and IC engine platforms.
• Defined process flow, tool concept, and die layout; validated formability and blank optimization for cost-efficient stamping.
• Guided tool suppliers in design validation, manufacturing, and tryout stages.
• Ensured adherence to quality gates, monitored tool readiness, and drove dimensional accuracy and first-time-right output.
• Attended and led T0/T1 trials, implemented correction actions, and ensured tool sign-off before SOP.
• Designed and reviewed welding fixture layouts, including robotic cells and CMM gauge integration.
• Finalized welding sequence, part locating, clamping strategy, and accessibility checks for ergonomic and dimensional integrity.
• Supported cell layout design, fixture BOM finalization, and supplier readiness audit.
• Tracked tooling milestones via APQP/PPAP gates, ensuring on-time delivery for major programs including TOYOTA, Ford, Bajaj, and Renault.
• Prepared and presented technical review reports, F-Events, and tool readiness reviews to OEM customers.
• Supported SOP readiness, QAV audit, and PPAP documentation for every new project.
• Conducted detailed tooling cost estimation – press tools, fixtures, gauges, jigs, automation.
• Collaborated with marketing and business development teams to win RFQs from global OEMs – BMW, Renault, Gogoro, Bajaj.
• Contributed to over ₹100 Cr worth of new business acquisition through technical proposals and cost-effective tool concepts.

• Make 2D And 3D design of press tools, Panel checker
• Prepare the flow chart & operation sequence sheet for part development
• Take design approval &make necessary correction if required
• Creation of detail drawings of tooling parts
• Prepare BOM & issued to manufacturing dept. For purchase raw material
• Release design and prepare operation sequence for each part
• Support the tool room team for manufacturing tooling component as per design
• Modified in design as per requirement of component behavior while developing parts
• Check tooling as per design & take trial for getting component as per requirement
• Experience of standard part utilization in dies and fixture such as MISUMI, PUNCH INDUSTRY
• Work on proto type tooling for various 2 Wheeler and 3 Wheeler parts
• Design press tool dies from 1 to 5 Ton with size 1800L x 1100Wx750H
• Make Progressive tooling of panel with zero scrap of sheets