SUNOJ KITTUNNI
Ipswich
Summary
Automotive Design Engineer with 12+ years of experience in system-level cost optimisation, reverse engineering and configuration governance across OEM vehicle programmes. Working knowledge of CATIA V5/V6, Teamcenter, 3DEXPERIENCE (3DX) and VisMockup for design validation, packaging reviews and assembly feasibility. Experience across Front End, Rear End, Seat and Underbody systems with focus on material optimisation, manufacturing simplification and structured engineering release.
Overview
14
14
years of professional experience
1
1
Certification
Work history
Senior Design Engineer – Cost Optimisation
Caresoft Global
2024.03 - 2025.12
- Led cost optimisation activities across BMW i5, Porsche Macan EV, GAC Aion, Nissan Qashqai and Renault Kangoo platforms.
- Executed targeted design modifications in CATIA across Front End, Rear End, Seat and Underbody systems.
- Proposed alternative materials and manufacturing process improvements resulting in up to 8–12% BOM optimisation.
- Identified part elimination and fastener reduction opportunities contributing to €800–€1,200 per vehicle savings.
- Validated proposals using Teamcenter, VisMockup and 3DX.
- Produced 3D printed prototypes using Bambu Lab to validate fitment before tooling decisions.
Senior Design Engineer – Reverse Engineering and CAD Development
Caresoft Global
2021.05 - 2024.03
- Developed detailed 3D CAD models in CATIA from teardown and scan data.
- Reconstructed complete assemblies and structured BOMs aligned to OEM standards.
- Evaluated material strategies and joining methods during benchmarking studies.
- Applied GD&T; and tolerance stack-up reviews to ensure dimensional compatibility.
- Developed alternative design concepts aimed at improving manufacturability.
Senior Officer – Technical Support and Field Analysis
TVS Auto Assist
2019.11 - 2020.11
- Investigated and documented technical faults through workshop duplication and validation testing.
- Analysed PDI reports, product failure data and warranty cases to determine root causes.
- Coordinated field feedback with R&D; teams to support product improvement initiatives.
- Inspected vehicles and conducted test drives to validate diagnostic findings.
- Provided structured technical support to dealer network and channel partners.
Team Lead – BOM and Configuration Management
OEC India Services – Ford Motor Company Programs
2012.02 - 2019.01
- Managed Engineering BOM to Service BOM conversion ensuring lifecycle traceability.
- Utilised Teamcenter and VisMockup for CAD validation and configuration checks.
- Controlled part number release and revision management.
- Executed engineering changes ensuring accurate downstream implementation.
- Verified configuration completeness prior to plant release.
Education
B.Tech - Automobile Engineering
Skills
- CATIA V5 / V6
- Teamcenter
- 3DEXPERIENCE (3DX)
- VisMockup
- Bambu Lab 3D Printing
- Design for Manufacture and Assembly (DFMA)
- Material Substitution and Process Optimisation
- BOM Optimisation and Engineering Change (ECR/ECO)
- GD&T; and Tolerance Review
- Continuous improvement initiatives
Certification
Six Sigma Green Belt
Accomplishments
- Delivered measurable BOM cost improvements (8–12%) through design and material refinement.
- Identified €800+ per vehicle cost optimisation opportunities during benchmarking studies.
- Supported EV and ICE vehicle programmes including BMW i5, Porsche Macan EV, GAC Aion, Nissan Qashqai and Renault Kangoo.
Timeline
Senior Design Engineer – Cost Optimisation
Caresoft Global
2024.03 - 2025.12
Senior Design Engineer – Reverse Engineering and CAD Development
Caresoft Global
2021.05 - 2024.03
Senior Officer – Technical Support and Field Analysis
TVS Auto Assist
2019.11 - 2020.11
Team Lead – BOM and Configuration Management
OEC India Services – Ford Motor Company Programs
2012.02 - 2019.01