Process & Quality Engineer — EV Systems

Manas
Asija

MS Mechanical Engineering, University of Michigan (4.0 GPA). Five years across TVS Motor Company, Bajaj Auto, and Tata Motors — driving quality engineering, EV NPI, and continuous improvement across automotive operations.

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94%
Warranty Cost Reduction
4.0
GPA at UMich
#1
of 109 Territories
001 — About

Engineering Precision.
Field-Proven Results.

Manas Asija
MANAS ASIJA

I am a Mechanical Engineering Master's student at the University of Michigan, graduating May 2026 with a 4.0 GPA. My focus spans automotive quality engineering, EV systems, battery technology, and smart manufacturing.

Before Michigan, I spent five years in the automotive industry across TVS Motor Company, Bajaj Auto, and Tata Motors — leading quality engineering, NPI launches, supplier quality management, and Lean Six Sigma improvement programs.

I hold a DFSS Black Belt (Six Sigma equivalent) from UMich and a Certified Project Manager credential. Open to full-time opportunities in process engineering, quality engineering, and EV systems.

SPC / DOE / PFMEA
APQP / PPAP
Lean Manufacturing
EV Powertrain Systems
Minitab / MATLAB
Power BI / SAP / SQL
Root Cause Analysis
Li-ion Battery Systems
GD&T / MSA / Gage R&R
Supplier Quality / SCAR
002 — Experience

Where I've Built.

AUG 2024 — MAY 2026
M.S. Mechanical Engineering
UNIVERSITY OF MICHIGAN, ANN ARBOR · GPA: 4.00/4.00
  • DFSS Black Belt project: reduced AIS 3+ injury probability from 96.8% to 24% using Taguchi L27 DOE and IDDOV methodology
  • Built CI Lens — AI-assisted analytics platform for RCA, SPC, and DOE workflows deployed with Prof. Hammett
  • Battery materials research: LFP and solid-state electrolytes via EIS, SEM, and thermal stability — ~12% ionic conductivity improvement
  • Earned Certified Project Manager credential (ENTR 560) — led GTM strategy for Saykal Electronics automotive radar
JUN 2023 — JUL 2024
Service Manager — NPI & Quality Engineering
TVS MOTOR COMPANY · HISAR, INDIA · iQube EV Launch
  • Identified TPS sensor failure root cause on iQube EV; drove D-clamp design fix reducing warranty costs by 94% (~$60K/month)
  • Developed SOPs piloted at 4–5 locations then scaled to 100+ dealerships; cascaded lessons learned to R&D for DFMEA updates
  • Improved First-Time Resolution from 75% to 97%; raised NPS from 28% to 70%
  • Achieved Rank 1 Regional in J.D. Power service satisfaction; zero major accidents in final 6 months
JAN 2021 — APR 2023
Service Manager — Process, Quality & CI
BAJAJ AUTO LTD. · RANCHI, INDIA
  • Led Lean Six Sigma across 8 service centers and 36 sub-locations; lifted OEE and quality KPIs by 15–20%
  • Achieved Rank 1 of 109 territories nationally in NPS growth; reduced field-failure recurrence by 20%
  • Drove 4-vendor ECU supply base diversification during 2022 semiconductor crisis — mitigating geopolitical supply risk
  • Certified 6 of 8 facilities for TPM; aligned audit frameworks to IATF 16949 standards
JAN 2019 — JUN 2019
Manufacturing Engineering Intern
TATA MOTORS LTD. · PANTNAGAR, INDIA · Powertrain Assembly
  • Performed PFMEA and investigated 275 non-conforming cases using SPC, Fishbone, and 5-Why
  • Conducted DFM reviews and supplier audits at in-plant vendor park; resolved top-tier head-cover quality issue
  • Stopwatch-based time studies and workstation balancing for powertrain line reconfiguration
003 — Projects

What I've Built.

DFSS Black Belt · UMich · 2026
Restraint System Optimization for Tall Occupants
Standard restraint systems failed to protect 95th-percentile (tall) males in frontal crashes — baseline simulations showed 96.8% probability of severe injury from airbag bottoming out. Applied IDDOV framework with Taguchi L27 orthogonal array DOE (27 runs vs. 243 full factorial), optimizing belt load limit, airbag flow rate, venting, and steering column force. Minitab analysis identified HIC as most sensitive to airbag venting; chest injury driven primarily by belt load limit.
AIS 3+ Injury Probability: 96.8% → 24.0% (PASS)
IDDOVTaguchi L27MinitabHIC / NijLS-DYNAFMVSS
Analytics Platform · UMich · 2025–26
CI Lens — AI-Assisted Continuous Improvement Tool
Co-developed with Prof. Pat Hammett (PhD) at UMich, CI Lens is an AI-integrated platform replacing specialty software like Minitab for Six Sigma and CI training. Supports ~100 tools across graphical analysis, SPC, hypothesis testing, regression, DOE, MSA, FMEA, VSM, and project management. AI-system-agnostic (ChatGPT, Copilot compatible). Deployed for UMich credit and professional education courses serving 400–500 students annually.
Deployed at UMich; validated against Minitab-equivalent industry tools
AI IntegrationSPC / DOERCA AutomationFMEA / VSMDMAIC / DFSS
Crashworthiness · UMich · 2025
Structural Crash Modeling & Vehicle Safety Analysis
Built and validated finite element vehicle crash models using HyperMesh and LS-DYNA, including ATD (Hybrid-III 50th and 95th percentile) modeling for occupant kinematics in frontal and side-impact scenarios. Analyzed NHTSA crash datasets in MATLAB to compute crush efficiency and validate energy absorption models. Applied FMVSS, IIHS, and NCAP safety regulation criteria throughout.
<5% error margin vs. experimental crash data
HyperMeshLS-DYNAATD ModelingMATLABFMVSS / NCAP
Battery Research · UMich · 2025
LFP & Solid-State Electrolyte Investigation
Hands-on research in Prof. Tang's lab investigating LFP and Cu-CNF solid-state electrolyte systems. Prepared electrolyte samples, performed Electrochemical Impedance Spectroscopy (EIS), SEM, and thermal stability analysis to characterize ionic conductivity and electrochemical performance. Achieved approximately 12% improvement in ionic conductivity through optimized electrolyte composition.
~12% improvement in ionic conductivity
LFP ChemistryEISSEMSolid-StateThermal Analysis
GTM Strategy · UMich ENTR 560 · 2025
Saykal Electronics — Automotive Radar Market Entry
Led U.S. and Canada go-to-market strategy for Saykal Electronics' automotive radar sensor product line. Delivered OEM and Tier-1 supplier segmentation, competitive pricing strategy, regulatory alignment (FCC, NHTSA, ISED Canada), and a phased market-entry roadmap. Presented directly to Saykal leadership. Earned Certified Project Manager credential through this program.
Roadmap presented to Saykal leadership · CPM credential earned
GTM StrategyOEM SegmentationFCC / NHTSAProject Management
Professional · TVS Motor Company · 2023–24
iQube EV Launch — NPI Quality & Warranty Reduction
Led incoming quality and NPI support during India's first mass-market electric scooter launch. Identified systemic TPS sensor failure via 5-Why and Ishikawa analysis, proposed D-clamp design fix with R&D. Authored SOPs piloted at 4–5 dealerships then scaled to 100+ locations. Lessons learned cascaded to R&D for DFMEA updates, achieving sustained warranty cost reduction.
94% warranty cost reduction · FTR 75% → 97% · NPS 28% → 70%
NPIRCA / 8DSOP DevelopmentDFMEAEV Systems
004 — Credentials

Certified & Recognised.

⬡
DFSS Black Belt
University of Michigan · Six Sigma Black Belt Equivalent
◈
Certified Project Manager
University of Michigan · ENTR 560
▣
Rank #1 of 109 Territories
Bajaj Auto · National NPS Growth
◉
Rank #1 Regional
TVS Motor · J.D. Power Service Satisfaction
◫
M.S. Mechanical Engineering
University of Michigan · GPA 4.00/4.00 · 2026
◧
B.E. Mechanical Engineering
Thapar Institute · Top 3% · ABET Accredited
005 — Contact

Let's Connect.

Open to full-time opportunities in process engineering, quality engineering, and EV systems. Based in Ann Arbor, MI — open to relocation.

masija@umich.edu
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