Sushanth is an engagement manager in our Dallas office. He partners with automotive and manufacturing clients on new product development, product strategy, cost engineering, and manufacturing and quality improvement.
With more than a decade of hands-on industry experience before moving into consulting, Sushanth combines deep technical expertise with the ability to bring leaders, engineers, suppliers, and shop-floor teams together around a shared goal — turning complex engineering challenges into practical, lasting results.
The best cost-reduction ideas rarely come from a spreadsheet. They come from getting engineers, suppliers, and operators in the same room and giving them permission to challenge how things have always been done
Sushanth leads teams through complex manufacturing challenges, from the engineering bench to the shop floor. While leading a value analysis and value engineering program for a major American engine and generator manufacturer, he brought together teams across the United States, France, and Italy, generated more than 1,400 ideas, and helped deliver approximately $85 million in savings and throughput gains.
When quality issues threatened a leading hot tub manufacturer, he assembled and led a cross-functional SWAT team on the shop floor, establishing a root-cause discipline that eliminated more than 1,000 hours of monthly rework and saved $5 million in warranty costs. He has guided a global logistics leader through the launch of a $2 billion new business unit and helped a major Japanese automotive OEM rethink its procurement and engineering approach, uncovering approximately $100 million in value.
Before consulting, Sushanth spent more than a decade as a product development engineer, designing engine and emissions solutions — work that resulted in three US patents for products that reduced costs by up to 50% across engine platforms.
He holds a bachelor's degree in mechanical engineering from the National Institute of Engineering in Mysore, India, a master's degree in automotive engineering from Clemson University, and an MBA from Northwestern University's Kellogg School of Management. He is fluent in English, Hindi, and German.