Priyanka Das

Achieving production targets in the automotive manufacturing industry is a complex and demanding endeavor, requiring a deep understanding of engineering principles, efficient processes, and adaptability to constant technological advancements. The motivation behind this submission is to share practical insights and firsthand experiences gained through navigating these challenges. I believe this knowledge can serve as a valuable resource for fellow engineers striving to optimize performance in similar environments, as well as for students and early-career professionals who are eager to gain a real-world perspective on what it takes to succeed in this dynamic and fast-paced industry.

A comprehensive understanding of various business aspects is essential for success in the manufacturing industry. The implementation of Lean Six Sigma principles can significantly reduce waste, boost productivity, and enhance product quality. Ensuring machinery complies with up-to-date safety standards not only protects workers' health but also contributes to job security, which in turn supports economic growth and fosters employment opportunities. Additionally, IoT-based manufacturing is revolutionizing the industry by turning conventional factories into intelligent, interconnected systems. Through real-time monitoring, predictive maintenance, and data-driven decision-making, IoT minimizes downtime, improves quality control, and optimizes resource efficiency. It also strengthens supply chain visibility and enables manufacturers to adapt more swiftly to changing market demands. Altogether, the integration of IoT is a driving force behind greater productivity, cost-effectiveness, and global competitiveness in modern manufacturing.

I am currently leading the launch of powertrain transmission manufacturing lines for Ford Cars. I have helped the team in successfully installing machines while maintaining the safety regulations put forward by NESC. I have also contributed to improving different manufacturing processes and reducing cycle times leading to increased productivity. I have been a crucial member of the production of F super duty trucks which is the US most wanted truck of 2024.

The automotive industry faces a variety of challenges, including equipment obsolescence. Drawing on my expertise, I have supported the team in modernizing outdated machinery to enhance operational efficiency and reliability. I have also played a key role in upgrading equipment to meet current NFPA safety standards. Additionally, I contributed to reducing cycle times, which significantly boosted production rates. Furthermore, I worked on improving traceability features—an essential element in ensuring consistent product quality and compliance.

Obsolescence is a major challenge faced by automotive companies, often impacting productivity and safety. Drawing on my expertise in electrical systems, I have contributed to upgrading machinery by replacing outdated components to meet current safety standards. Achieving the desired cycle time is another critical challenge in manufacturing. By thoroughly understanding the process and implementing effective industrial control systems, it becomes possible to optimize operations and consistently meet production targets.

I have helped the team to improve the traceability feature which is a key factor to maintaining quality.

I see my innovation as a key contributor to reducing cycle time in manufacturing by optimizing workflows, eliminating process inefficiencies, and leveraging real-time data for faster decision-making. By integrating smart automation and Lean principles, the solution streamlines operations from raw material input to final product output. This not only accelerates production but also ensures consistent quality and reduces downtime. In the long term, reducing cycle time will allow manufacturers to respond more quickly to customer demands, increase throughput, and maintain a competitive edge in a rapidly evolving industry.

One of the most exciting trends in manufacturing right now is the rise of digital twin technology and its integration with AI-driven predictive analytics. The ability to create a real-time digital replica of a machine or an entire production line allows for proactive decision-making, remote monitoring, and optimization with a level of precision we’ve never had before. It not only reduces downtime but also enhances quality and safety—two critical factors in any manufacturing environment. Another game-changing development is the shift toward smart, connected systems through Industrial IoT. The sheer volume of data we can now collect from equipment, processes, and operators enables continuous improvement through better traceability, transparency, and automation. These technologies directly influence my work by allowing me to design more intelligent control systems that are both responsive and adaptive. Lastly, I’m deeply excited about sustainable manufacturing practices, including energy-efficient automation, waste reduction through Lean principles, and the adoption of eco-friendly materials. These advancements align with the growing industry focus on environmental responsibility and help make manufacturing not just more advanced—but more ethical and future-focused.

Anchor your research in real manufacturing challenges—whether it's reducing cycle time, improving quality, enhancing flexibility, or optimizing energy usage. Spend time on the shop floor, interview operators and engineers, and observe pain points first-hand. Apply Lean Manufacturing principles like waste reduction, continuous improvement (Kaizen), and Just-In-Time delivery.