SHASHANK KARNIK

Troy, MI 48085
248.879.7084-home / 248.686.4632-cell / skarnik@sbcglobal.net

PRODUCT DEVELOPMENT / PROJECT MANAGEMENT

Expertise in: Plastics / Composites Engineering Project Management / Product Innovation
SUMMARY OF QUALIFICATIONS

 Seasoned executive with 20+ years of experience elevating performance and productivity of multibillion-dollar corporations through
skillful design/execution of advanced engineering and technical processes.
 Well-equipped with MBA in Operations Management and MSE in Manufacturing Systems Engineering; as well as key
strengths in process improvement/re-engineering and project/program management.
 Combines diverse, international operations expertise with history of accomplishment in new product innovation and front-end
engineering/design (FEED) to provide competitive advantage in market place.

P&L Management Design for Six Sigma (DFSS) Supply Chain

Strategic Direction Technology Implementation Value Engineering
Design Optimization End-to-End Project Lead Quality Assurance
Resource Maximization Operational Excellence Process Engineering
Proven performer in diverse highly technical situations with results including:
 Designed and implemented new product plans for next generation products and technologies.
 Successfully managed product development from concept to production with close attention to budget, timing, quality, product
specifications, and government regulations for 3 distinct vehicle interiors on 1 common platform.
 Championed construction of division's technology infrastructure from ground up for $billion+ corporation.
 Received concept and implementation readiness approval for hybrid structure that became design standard.
 Co-authored and presented technical paper at conference on hybrid structure "Development of Lightweight, Hybrid Steel / GMT
Composite IP Carrier to meet World Crash Requirements on Passenger Vehicles."
PROFESSIONAL EXPERIENCE
Plasan Carbon Composites - Division of Plasan SASA / 2010 – Present
Tier 1 supplier of carbon fiber components and assemblies in United States
CONSULTANT
 Support marketing and business development teams in analysis, identify new markets, products and acquisition opportunities.
 Provide technical expertise in development of new products and scalable processes for automotive, and defense industries.
 Provide guidance during front-end engineering and design (FEED) of advanced composite & hybrid material structural components.
 Mentor/teach project teams on all aspects of Program Management for integrated systems.

TATA Auto Comp Systems Ltd. / 2007 – 2010

$62B+ Global Group of Companies
DIRECTOR OF TECHNOLOGY (1/2007- 6/2009) / DIRECTOR OF SALES & MARKETING-U.S. Based (7/2009 - 2/2010)
 Identified and assessed new markets, product and acquisition opportunities that will contribute to growth.
 Controlled and monitored program execution of all North American projects, which included automotive components and subsystems,
contract design services, product testing services and engineering consulting services.
 Managed Engineering Business Unit with 250+ Engineers in 8 departments (R&D, Advanced process Engineering, Project
Engineering, Tooling Engineering, Testing, Purchasing, HR, and Finance).
 Defined/directed all technological planning and development functions; built capacity/functional competency for specific areas;
designed/executed product plans, technology road maps and product development process; identified/evaluated new non-organic
growth opportunities with new products and technologies.
 Led major project development; reduced engineering and product development cost per program.
Accomplishments:
 Improved operational efficiency of the business unit by deploying standardized engineering and business processes and
optimizing resource utilization, resulting in 20% increase in EBIT from operations.
 Led product development/launch of 23 automotive interior/exterior projects with full QCD responsibility. Products include small
plastic and metal precision components to cockpit, door and bumper systems.
 Successfully developed and launched seamless air bag, LPM (Low-pressure Molding), IMG (In-mold Graining) and IMD (In-
mold Decoration) process technologies meeting European requirements for passenger vehicles for export market.
 Designed components using alternate material (paper honeycomb core sandwiched between glass matt bound by
polyurethane foam) in cooperation with European University. Material provides best Cost to Weight ratio, high bending
performance, compression properties and flexibility to change matrix layers to get desired properties.
 Shashank Karnik
Career Progression Continued / Page 2
TATA Auto Comp Systems Continued:
 Developed thermoplastic impact energy management system solution for bumpers ( in cooperation with NetShape, U.S.A.)
to meet FMVSS requirements in North America. Achieved 30% increase in absorption efficiency giving greater performance
with less package space.
 Created plastic tailgate module concept to replace sheet metal. Module provides 5-7% cost savings, 25% weight reduction,
and led to increased fuel efficiency, improved acoustics, low impact dent resistance, and part integration and styling flexibility.
 Developed/presented strategic plan for next generation products/technologies.
 Launched research project in collaboration with material supplier to develop nano clay composite material for automotive
exterior parts; resulting in 15% cost reduction and 30% weight reduction.
 Initiated development of complete state of the art testing facility.

Faurecia Interior System / Auburn Hills, MI / 1998 – 2006

Division of $11B+ Global Component & Systems Manufacturing
Progressively advanced with increased responsibilities and accomplishments.
DIRECTOR OF ADVANCED ENGINEERING (2005-2006)
 Led/guided product innovations for NA division; ensured intellectual property protection and technology transfer/deployment.
 Provided technical direction for new business development; identified/analyzed opportunities to build purposeful relationships, led
technical discussions with customers and technical leaders in European R&D centers.
Accomplishments:
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 Designed/launched olefinic bi-laminate skin technology with seamless airbag system; 1 to implement in industry.
 Developed/implemented comprehensive product strategy for NA market, achieved $35million/year sales increase.
 Played key role in securing contracts for 2 instrument panels ($50MM/year) and door trim panel ($20MM/year).
 Directed design optimization using predictive analysis of common cockpit structure for 3 distinct product lines meeting all
customer/regulatory requirements; considered benchmark for mid-segment vehicles within OEM.
 Initiated research project in technical collaboration with major material supplier, developing urethane skin technology to gain
competitive advantage (saving $10/unit).
 Led specification, supplier selection and approval of airbag deployment test facility.
DIRECTOR OF ENGINEERING (2001-2005)
 Ensured compliance of product and process with relevant customer and regulatory requirements.
 Directed continuous management of products in development cycle and cost effective solutions for productivity improvements.
 Established contacts and customer R&D leaders; ensured smooth transfer of new technologies and deployment.
 Led technical teams toward new business acquisition.
 Established and maintained department’s annual budget ($6M).
Accomplishments:
 Successfully managed product development from concept to production with close attention to budget, timing, quality, product
specifications, and government regulations for 3 distinct vehicle interiors on 1 common platform.
 Built division’s technology infrastructure from ground up; established local network of experts in materials, safety, CAE,
airbags, and surface technologies.
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 Successfully transferred and deployed industry 1 “Rail-less Window Regulator System” into 2 composite plastic door module
concepts. Won 2006 SPE (Society of Plastics Engineers) innovation award.
 Received concept readiness and implementation readiness approval for hybrid (metal and long glass fiber composite) cockpit
structure from Ford Motor Company, which became design standard.
 Directed technical team to develop 2006 PT Cruiser interior from acquisition to production within aggressive timeframe.
 Implemented PLM (Product Life Cycle Management) system, resulting in 20% improvement in development efficiency.
 Co-developed and launched low-pressure injection molded door panel with in-mold decoration for large OEM.
ENGINEERING MANAGER (1998-2001)
 Provided technical support for new business development and advanced engineering activities across various OEMs.
 Responsible for Product & Process development to ensure performance, timing, and cost targets.
Accomplishments:
 Built complete new product design and engineering team from ground-up.
 Won design competition for $400MM development/manufacturing contract for 2 vehicle interiors from global OEM.
 Led technical team to develop and launch complete door system program for two Ford vehicles in Brazil.
 Obtained concept/implementation approval for level 1 cockpit module from Ford Motor Company to bookshelf technology.
 Acquired, developed, and flawlessly launched Saturn ION hard instrument panel program ($20 million/year) with seamless
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airbag technology; concept to launch in 13 months (1 time in North America). Selected as finalist for SPE innovation award.
 Shashank Karnik
Career Progression Continued / Page 3
ADDITIONAL CAREER PROGRESSION
SENIOR PRODUCT ENGINEER
Textron Automotive / Auburn Hills, MI / $10B+ Global Component & Systems Manufacturing
 Designed/developed instrument panel structure using engineered plastic and magnesium to meet all crash, airflow, and
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durability requirements; maintaining 80% of cockpit interfaces. 1 all plastic structural duct assembly replacing steel beam.
 Co-developed (with suppliers) vibration weld specifications and testing procedure to validate structural design.
 Established error-proofing process for structural duct assembly.

LEAD PROGRAM ENGINEER

Aeroquip Corporation / Auburn Hills, MI
 Headed product and process development, project management; ensured product met all performance, timing, quality, and
cost targets. Successfully managed several interior component programs for Asian and North American OEMs.
 Team leader for developing ergonomically designed backlit displays and graphics.
 Lead engineer on rapid tool development using orbital and NVD process.
 Coordinated with equipment and material suppliers to improve product performance and quality by using SCORIM process.

GRADUATE RESEARCH ASSISTANT

University Of Michigan / Dearborn, MI
 Studied effect of washer design on fatigue life failure modes and torque retention of bolted joints between composite and steel.
 Researched literature for measurement and scaling techniques of customer perception of quality using human factors,
statistical, marketing and psychology models.

MANUFACTURING-TECHNICAL MANAGER
Chanrai Chemicals / Sierra Leone, West Africa / Consumer Electronics and Packaging Manufacturing
 Responsible for technical analysis, cost proposal and selection of HMHDPE Film and HIPS profile extruders for plant
expansion. Oversaw planning, organizing, directing and controlling all engineering/manufacturing activities of 250 employee,
3-shift injection and extrusion product operation producing basic and sophisticated packaging and consumer electronics
products.
 Cut machine down time by installing electronic timers gaining 2 out of every 16 hours.
 Engineered significant efficiencies in equipment and materials, reducing rework 30%.
 Improved facility design and implemented cell concept using Group Technology.

SENIOR ENGINEER
Vifor Laboratory / Bombay, India / Medical device manufacturer
 Designed and developed flow control valve for IV kit.
PROFESSIONAL DEVELOPMENT, AFFILIATIONS & RECOGNITION
Masters in Business Administration—Operations Management (Honors) / York College of Pennsylvania
Masters in Science—Manufacturing Systems Engineering (Honors) / University of Michigan
Bachelor of Engineering—Plastics Engineering (Honors) / Mafatlal Polytechnic
Society of Plastics Engineers / Society of Automotive Engineers / Society of Manufacturing Engineers

Lectures / Publication:
 Presented technical paper at 2005 SAE Congress and SPE (Society of Plastics Engineers) conference on hybrid structure
“Development of Lightweight, Hybrid Steel / GMT Composite IP Carrier to meet World Crash Requirements on Passenger Vehicles”
 Selected on supplier panel for SAE Congress conference sessions to discuss various topics ranging from design enablers, cockpit
architecture to perceived quality and craftsmanship.

Additional Specialized Knowledge:

 Electronic Maintenance (ICS – UK), TQM, QFD, Project Management, Manufacturing Automation, Group Technology, Lean
Manufacturing, Six Sigma, DFSS, Faurecia Excellence System, Tata Business Excellence Model

Process Knowledge:
 Injection Molding  Compression Molding  Low Pressure Molding
 Vacuum Forming  Plastic Welding & Joining  Assembly/Automation
 Pressure Die Casting  Autoclave & RTM  Surface Decoration

Languages:
 Oral and Written Fluency in English and Hindi
 Extensively traveled in U.S., India and Europe (Germany, France, Spain, England) Japan, China

United States Citizen