Highly dedicated, motivated, independent and result oriented 20+ years of design and development experience in Automotive, Locomotive, Heavy engineering, and Aerospace, along with the Manufacturing experience. EXPERIENCE SUMMARY:

• Worked for major OEM clients including General Motors (GM), Ford, Honda, and Toyota in the USA; Terex in India; Alstom in India and Belfort, France; B/E Aerospace in India; and ZF/TRW Automotive in Suzhou, China, and the USA.

• Extensively worked on Design of Exterior (BIW - Sheet metal), Interior (Plastic), Castings

• Worked on BIW structural design calculations for Outrigger and development for Terex cranes, utilizing UG NX software for designing checker plates, fenders, bumpers, soft and hard trims, sheet metal parts, and ladder design.

• Executed interiors for Alstom trains in France, Europe, for approximately one year, involving plastic parts, sheet metal operations, and welding.

• Extensive experience in resolution skills for production issues arising from both plant and supplier sources, including part validation testing, result analysis, and the implementation of design improvements. Proficient in cost reduction techniques, quality improvement strategies, prototype design, benchmarking, and competitor analysis.

• Expert in Catia V5, V6, Unigraphics NX, Solid works and PLM tools (Team Center, DMA 2.3 Enovia – VPM).

• Strong product design and development, manufacturing, as well as various related processes such as Design for Manufacturability (DFM), Design for Assembly (DFA), Design Failure Mode and Effects Analysis

(DFMEA), Design Verification Plan and Report (DVP&R), and Process Failure Mode and Effects Analysis

(PFMEA)..

• Expert in 3D Design modeling methodologies, surfacing approach, assembly and manufacturing drawings with GD&T in CAD software’s with customer’s specific standards

• Worked with Borewell Drill bit’s manufacturing company Master Mining Equipment’s (MME).

• Experience in modularization, Product development and Tear down projects

• Experience in handling Engineering BOM and Manufacturing BOM.

• Knowledge on GD&T and Tolerance Stack up analysis.

• Involved in various engineering tests such as EMC testing, Shipping and storage test, Water dripping test, Dust spray test, Hight and Low temp test. CAD SKILLS SUMMARY:

• CATIA V5 : 10 Years, Unigraphics NX : 8 Years and SolidWorks :2 Years.

• Worked with modules in CATIA V5 and Unigraphics NX, including Part Design, Generative Shape Design, Sheet Metal Design, BIW Automotive, Assembly Design, Wiring Harness, Digitized Shape Editor, Quick Surface Reconstruction, Digital Mockup, and Drafting.

• Worked PLM Databases at client place : Team Center, VPM, Enovia, Darwin and DxEEP. PATENTS :

• Awarded patent for Heat sink, Patent no: USD793350 RAJAGOPAL KENCHAPPA

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WORK EXPERIENCE:

SATVEN., Troy, MI

DENSO International America – Michigan, USA

Design Engineer

Jan2014 - Present

Contributed to the design of CCP, ADAS Radar, Head-Up Display (HUD), and Cluster systems. Executed HUD Programs A1XX, E2LB, E2SB, C1UL, C1TL, A2LL, A2SL for General Motors (GM); TJBA, TGVA, TYAA, and T90A for Honda; 500B and 780B for Toyota; U554, P708, and P702 for Ford customers. I have utilized 3D CAD tools, including CATIA V5 and Unigraphics NX (UG NX).

• Design and Packaging: We conduct a thorough initial study of the optical path based on customer input to align with vehicle data, determining whether a side-fold or down fold HUD configuration is suitable, ensuring adequate clearance. Subsequently, we initiate the development of internal and external component for Request for Quotation (RFQ) and prototype models. Additionally, I’m involved in the preparation of presentation and detailed bill of material.

• Customer relations: Involving weekly customer meeting to address project status, concerns, design completion dates, anticipated issues, any material change is an effective way to ensure transparent communication and keep all stakeholders informed.

• Releasing Activities: After well-defined product development, involving Teamcenter for design, drawing creation for both single part and assembly, releasing the drawing in the Teamcenter and utilizing Darwin for plant access to released drawings. Our plant start looking for the suppliers after releasing the drawings.

• Supplier relations: Engaging in supplier meeting to discuss sink marks, parting lines, any draft and thickness change, gate locations and to discuss part ejection issue from the die, etc.

• Testing: Conducting thorough tests on physical part, including measuring the ghost Images, light Intensity, thermal test at varying temperatures, water and dust tests, aligns with meeting customer specification. Measuring light intensity post-tests is a key step to validate image quality and overall product performance.

• Engineering Change Request: Regularly updating and releasing engineering changes in alignment with customer requirements at each build stage, while also addressing any internal modifications, ensure a responsive and adaptive approach to meet evolving project needs and maintain product quality.

• Thermal / Cooling Design: Implemented thermal cooling methods for the aluminum PCB and Graphic Processing Unit (GPU), utilizing various concepts such as Thermal pads, Thermal gel, and heat sinks by using CATIA V5.

• Wire Harness: Done Flat Flexible Cable (FFC), Flexible Printed Circuit (FPC) and Wire routing from main PCB to stepper motors and TFT displays.

ZF / TRW Automotive, Michigan, USA

Design Engineer

May 2012 – Jan2014

• Michigan, USA: Involved in design activities related to the steering wheel clock spring, study the failure modes, and proposing solutions demonstrates a proactive approach. Discussing proposed changes with the hardware team and obtaining confirmation before implementing design modifications ensure a collaborative and validated resolution process.

• Suzouh, China: Incorporating proper snaps and guide mechanisms in the design of seat memory and Door warning switches. Ensure both design and manufacturing feasibility is checked indicates a comprehensive approach to deliver functional and manufacturable components. B/E Aerospace, Hyderabad, India,

Senior Design Engineer

October 2011 – June 2012

– Contributed Design and development work for SFC (Super first-class seatings) and semi-SFC seatings, Interior seat cabins for renowned airlines like Thai Airways, Etihad Airways and Emirates Airways. I have utilized 3D CAD tools Unigraphics NX (UG NX).

• Arm Rest Design for Thai Airways: Scope of this project was Design of Arm Rest to withstand 8g force, incorporating an actuator for multiple positions (TTOL, Bed, dinner, and lunge), aligns with comprehensive project scope. The use of sheet metal models based on Customer specification and its actuation system designed to move the Armrest to different position as per the requirement. Interactive design review has done by the Analysis team and our USA team to match the requirement. Created the detailed drawings as per the BE Aerospace standard.

• Privacy divider design for Etihad Airways: The project scope involving the design of a privacy divider between two seats, considering safety measures, and incorporating features like handles and dampers for passenger safety. Interactive design review with the analysis and USA teams’ alignment with requirement. And creation of detailed drawings as per the BE Aerospace standard. Released the product drawings to manufacture in Teamcenter.

Cyient / Infotech Enterprises Limited., Bangalore, India

Team Leader

August 2005 -September 2011

Worked as a Team Leader around 6 years at Infotech Enterprises limited in various fields like Locomotive, Heavy engineering, got opportunity to work in Belfort, France. I have utilized 3D CAD tools, including CATIA V5 and Unigraphics NX (UG NX).

TEREX – Ohio: It is heavy engineering cranes manufacturing company. We involved outrigger, Boom Rack, fender, and Bumper design for BT-45 crane.

• Design and Packaging: Customer is provided the Slew ring, Footprint area and Concept load chart, by using these inputs started all reaction calculations, in similar way we calculated reaction loads for 16 cases at different Boom position and pay load carrying capacity. Then we selected the material and freeze the cross-sectional area for front, rear of the outrigger arms.

• Customer relations: Involving customer meeting to discuss status of the project, concerns, design completion dates, expected issues, any material change.

• Support to Analysis team: After the final design, we provided our final models to analysis team to cross check the designed cross sections to withstand the given loads.

• Releasing Activities: After the design of final product in the Teamcenter, we start creating the drawings for both single part and assembly except the standard parts. Then we will start releasing the drawing in the Teamcenter.

• Thermal Cooling and Packaging: Completed packaging and thermal cooling for lithium batteries in Terex BT-45 and BT-60 trucks.

ALSTOM., Belfort – France: It is locomotive manufacturing company. We involved in the designing of internal components for power car of the train. Executed TGVA train packaging, COCO and BOBO power trains

• Design and Packaging: We Study the available area to install new equipment and prepare the mounting design concepts as per the requirement for the products like VTMT, Auxiliary blocks, Control panel. Etc., After finalizing the mounting concepts, we upload the designed mounting to PSN structure and start updating the drawings. Released the product drawings to manufacture in the Teamcenter. Inspect the final product in the shop floor frequently.

Sidus Infotech Pvt. Ltd., Bangalore, India

Team Member

April 2005 – August 2005

• Design and Detailing: Involved designing the various mounting concepts for the equipment’s depending on the available space and weight of the equipment. Updating detailed drawing for the new mountings and releasing those drawings to the manufacturing plant. and we do inspect at the time installation. I have utilized 3D CAD tools Solid works. Amazon Envirotech Pvt. Ltd., Bangalore, India

Trainee Engineer

June 2004 - April 2005

• Modeling and detailing task: This project we provided the new mounting concepts for the products like filter, compressor and stirring machines depends on the available space, Space is the main criteria for these projects. After finalizing the mounting concept, we release the drawings for the production and inspecting the products at the time of fabrication and installation of the product in the plant. Utilized 3D CAD tools including Solid works.

EDUCATION:

• Master of Technology - Aeronautical Engineering June 2008 - April 2010

• Bachelor of Engineering - BE, Mechanical Engineering June 1999 - April 2003

• Diploma of Education - Mechanical Engineering

June 1996 - April1999

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