Ajinkya Dharmraj Sonwane
Vehicle Systems Lean Material Execution Engineer @General Motors
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WORK HISTORY
Vehicle Systems Lean Material Execution Engineer @General Motors
US
New EV Launch & Material Flow1. Set up 55 material stations across Chassis and Doorline for a new EV model, specializing in batch stations for parts like steering wheels and ORVMs.2. Designed the aisle network and flowracks based on part routing, maintaining a 3-hour buffer and strict FIFO to prevent dead-end storage and rework costs.3.Managed the installation packages for the physical layout, including the demo and painting of the aisle networks.PFEP & Data Automation1. Maintained the PFEP for 500+ chassis parts, tracking dimensions, delivery methods, and inventory levels.2. Built a custom VBA timestamp function to automatically track changes in critical data like part numbers and packaging types.3.Improved data traceability and version control, shifting the team from manual updates to a more reliable, automated planning system.Digital Transformation & Process Optimization1. Digitized the plant-wide labeling process by replacing manual paper labels with a centralized E-label automation system.2. Developed a high-integrity data pipeline in VBA that manages 500+ parts, ensuring 100% accuracy before server uploads.3.Reduced manual data entry errors and eliminated the lead time required for physical label printing and distribution.
EDUCATION
Savitribai Phule Pune University
Bachelor of Engineering - BE, Instrumentation and Control Engineering
San José State University
Master's degree, Industrial Engineering
COEP Technological University
Master of Technology - MTech, Instrumentation and Control Engineering
ABOUT AJINKYA DHARMRAJ SONWANE
Engineer by training, problem-solver by instinct.I work at the crossroads of manufacturing, material flow, and intelligent systems—where every small inefficiency is a story waiting to be rewritten.From the shop floor to high-level strategy, I’ve spent years learning how parts move, how decisions ripple, and how the right packaging isn\'t just a container—it\'s a system. Now, I’m building tools that blend AI and industrial insight to make those decisions smarter, faster, and more human-aware.I\'m not chasing buzzwords. I’m here to make the real-world smoother—one flow, one prediction, one well-placed question at a time.
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