Kabhir Das Sarna
Birmingham,United Kingdom
Summary
Results-driven Manufacturing Engineer with a strong background in precision assembly, robotic systems, and lean process optimisation within automotive environments. Proven ability to align manufacturing processes with design intent, having led complex line setups, takt-time rebalancing, and over 50 engineering change implementations.
Experienced in CNC machining, 3D printing, and adhesive bonding, with a track record of reducing waste, improving uptime, and delivering measurable savings. Strong collaborator across design, quality, and production teams, skilled in rapid issue containment, documentation, and continuous improvement. Thrive in high-performance, fast-paced settings with a focus on quality, efficiency, and innovation.
Overview
8
8
years of professional experience
8068
8068
years of post-secondary education
Work history
Manufacturing Engineer
London EV Company (LEVC)
Coventry
07.2022 - 07.2025
- Develop, optimise, and implement manufacturing processes across vehicle assembly and body structures, ensuring efficiency, quality, and alignment with design intent and HSE standards.
- Led robotic adhesive bonding operations, owning bead path programming and optimisation—cutting material waste by 45% and improving cycle efficiency.
- Department lead for DC tooling: managed 300+ tools, resolved repetitive failures, reprogrammed tools per operator feedback, and ensured high assembly reliability.
- Executed process time studies and live line rebalancing (52, 85, 109 min cycles), creating achievable man assignments in collaboration with production teams.
- Delivered over 50 PUCR/ECR changes, owning engineering change management system and maintaining SWES documentation across 10k+ process elements.
- Led 15+ line trials with engineering and quality teams, ensuring seamless integration of changes and high product quality.
- Created operator guidance systems for 45+ stations; developed new end-of-line repair stations integrated with digital tracking tools.
- Subject Matter Expert (SME) for 3D printing and rapid prototyping, supporting production tooling and fixtures—saving over £40,000 to date.
- Designed jigs using CATIA for engine assembly, preventing part damage and saving £15,000 annually as part of CI project.
- Owned and maintained SORION and WAHA systems, ensuring test rig uptime, resolving faults, and leading supplier communications.
- Led ANDON reduction project on Body Structures line, implementing fixture modifications that reduced ANDON calls by 68%.
- Managed VCATS testing and change control, standardising fault reporting and mentoring junior engineers in structured problem-solving.
- Led critical spares and equipment classification project, establishing spares inventory and lead times—enabling accurate budget forecasting.
- Conducted health & safety risk assessments, documented process workflows, and ensured ISO 9001 compliance during internal and external audits.
- Mentored apprentices and T-Level students, coordinated CSR events (raising £5,000 for RNID), and served as LEVC’s departmental ISO9001 rep.
- Member of LEVC’s 1% Leaders Group, contributing to cross-functional leadership and organisational development initiatives.
Production Engineer
Iota Print Limited
London
11.2020 - 03.2022
- Led full setup of manufacturing facility, installing UV Glass Printing and CNC Machining lines using lean, uni-directional workflows to maximise space and efficiency.
- Partnered with Design and Assembly teams to align processes with design intent, integrating Design for Assembly (DFA) principles to reduce rework and improve build quality.
- Developed and maintained assembly processes, including jigs, fixtures, and standard work, supporting repeatable, high-precision builds.
- Implemented a 2-phase Andon system for real-time issue visibility and rapid containment of production disruptions.
- Applied cycle time and takt time analysis to implement a pull-based system with JIT material flow, ensuring alignment with production demand.
- Conducted PFMEA and risk assessments to strengthen process robustness and ensure quality assurance in high-mix CNC environments.
- Led in-house 3D printing setup and support, producing tools and packaging that saved £900/month while increasing responsiveness to internal needs.
- Launched a SolidWorks-based CNC design service, delivering parts to 78 clients with 100% satisfaction, generating £20,000 in revenue.
- Supported rapid root cause investigations and collaborated cross-functionally to deliver effective countermeasures and minimise downtime.
- Promoted a continuous improvement culture, driving lean initiatives and process refinements across assembly operations.
- Proficient in SolidWorks, CNC operations, additive manufacturing, and Microsoft Office Suite.
Intern
Sterling Tools Limited
Faridabad
11.2018 - 07.2019
- Researched electric propulsion components and developed designs for swappable battery systems using SOLIDWORKS.
- Tested and analyzed product performance, ensuring compliance with quality benchmarks.
- Spearheaded project for setup of High Voltage Lab facility as per business requirement from planning to execution till completion of establishment.
- Corporate representative at The Electric Vehicle Exhibition 2019, showcasing product innovations.
Project Intern
Indo Autotech Limited
Faridabad, India
01.2018 - 05.2018
- Performed route cause analysis for reducing paint scratch defects from 15 to 1 per 100 handle bars.
- Applied DMAIC framework to improve over all process efficiency by 15% performing Line Balance & creating new Subassembly stations.
- Control plans implemented and project handed over post completion.
- Conducted regular supplier audits, ensured adherence to company quality standards.
Process & IT Intern
VECV (Volvo & Eicher JV)
Pithampur , India
06.2017 - 07.2017
- Created Workflow Steam Maps & Spaghetti Diagrams for HD and Engine assembly lines.
- Utilised FMEA methodologies, mitigating potential risks during manufacturing phase of new HD line
- Part of SAP MES first response team providing ANDON support solving daily production meeting 100% target response & resolution time
- Participated in quality audits and worked towards achieving ISO certification.
Education
Masters - Mechanical Engineering and Management with Industrial Internship
Queen's University Belfast
Belfast01.2021
Bachelor of Science - Automobile Engineering
Manipal University Jaipur
07.2018
A- Levels - Engineering
DPS Faridabad
Faridabad03.2014
GCSE -
DPS Faridabad
Faridabad03.2012
Skills
- Process Improvement
- Technical Proficiency
- Data-Driven Analysis
- Team Collaboration
- Industry Knowledge
- MS Office
- Process planning
- Manufacturing systems integration
- Manufacturing process controls
- Personnel Management
- Critical and analytical Thinking
- Problem-Solving
- Quick learner
- Works well in diverse team environment
- Strong communication
Custom
Summer Intern, 06/16, 07/16, Berger Engines, Rolls Royce Power Systems, New Delhi, India, Researched power generation systems and created AutoCAD layouts for P&ID diagrams., Identified safety hazards and implemented improved measures for a live project in Bangladesh.
Timeline
Manufacturing Engineer
London EV Company (LEVC)
07.2022 - 07.2025
Production Engineer
Iota Print Limited
11.2020 - 03.2022
Intern
Sterling Tools Limited
11.2018 - 07.2019
Project Intern
Indo Autotech Limited
01.2018 - 05.2018
Process & IT Intern
VECV (Volvo & Eicher JV)
06.2017 - 07.2017
Masters - Mechanical Engineering and Management with Industrial Internship
Queen's University Belfast
Bachelor of Science - Automobile Engineering
Manipal University Jaipur
A- Levels - Engineering
DPS Faridabad
GCSE -
DPS Faridabad
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