Sushma Mallula

About Sushma Mallula

Professional automotive design engineer with 5 years of experience specializing in exterior automotive lightingseeking a challenging position in lighting design to enhance vehicle safety.• Collaborative design and development experience in Planning, performing, and delivering exterior lighting projects in alignment with the program timing, development schedule, and budget established by the customer and the program launch team.• Expert in the product design and development process for interior hard trim, seat trim & automotive plasticcomponents.• As a Master’s Graduate Mechanical Engineer, I possess comprehensive knowledge in the design and manufacturing of automotive plastic components with experience in injection molding process.Technical Skill Set:• CATIA V5, UG-NX, Auto CAD, Solid works, Autodesk Fusion 360, Hyper mesh.• Ford Platform: Team Center, Vehicle Part Progress (VPP), Worldwide Engineering Release System (WERS) Concerns, WERS Alerts, International Material Data System (IMDS), Appearance Approval Report (AAR), Product Part Approval Process (PPAP), Special Characteristics Communication Agreement Form (SCCAF), Advance Product Quality Planning (APQP), EAPQP, Failure Mode & Effects Analysis (FMEA), GD & T, Tolerance Stack up, Design Validation Plan and Report (DVP & R), Global Color Management systems (GCMS).Professional Certifications• Auto CAD• Auto Desk Fusion 360• SCAFF Build • EAPQP• APQP• WERS Basics• WERS concerns • WERS Alerts • FEDE - Team Center Engineering for CAD users• FEDE - Team Center Security for End Users• DMAIC 6-Panel Introduction and Overview• Failure Mode & Effect Analysis (FMEA)• Vehicle Part Progress (VPP) and Manufacturing

Experience

1. Nafta Vave Engineer

   Marelli

   Jul 2024 — Present · TN, US

   Automotive Exterior Lighting Driving cost-saving measures, coordinating workshops, and ensuring engineering excellence within the automotive lighting sector.>Lead VA/VE Initiatives: Perform and lead Value Analysis and Value Engineering activities to identify cost reduction opportunities in automotive lighting components.>Idea Generation and Proposal: Participate in VA/VE activities, propose innovative ideas for cost reduction, and ensure alignment with engineering and production standards.>Workshops Coordination: Lead internal, supplier, and customer workshops to identify cost savings and eliminate waste using VA/VE methodologies across the entire value stream.>Mold Tryout Coordination: Manage mold tryout, resin sampling, and mock-up processes, ensuring alignment with design and manufacturing needs.>Cost Reduction Assessment: Review cost reduction recommendations, providing engineering assessments and implementation plans to ensure feasibility and effectiveness.>Problem Solving: Investigate and propose engineering solutions for manufacturing and field issues, focusing on material efficiency and design optimization.>Feasibility Analysis: Participate in technical reviews of proposed ideas and solutions, ensuring feasibility from an engineering and production standpoint.>Material Standards Review: Assess and standardize material use for automotive lighting applications; investigate alternate materials such as plastics and resins.>Validation and Testing: Develop validation and test plans for new designs or design changes, coordinating with testing facilities to ensure compliance with quality standards.>Financial Analysis: Conduct financial analyses of ongoing and future projects to measure the impact of VA/VE initiatives on cost savings and overall value improvement.>Annual Project Planning: Develop and execute annual project plans with suppliers, targeting year-over-year cost improvement through VA/VE activities.

Education

• Jawaharlal Nehru Technological University, Kakinada

  Bachelor of Technology - BTech, Mechanical Engineering

  2010 — 2014

• Wayne State University

  Master's degree, Mechanical Engineering ( Specalized in Design and Manufacturing)

  2016 — 2017