Summary

**** ***** ** ********** ** Diesel engine fuel injector product design and development with 6Sigma Green Belt certification

**** ***** ** ********** ** solid modeling, part detailing and assembly drawings using Pro Engineer Wildfire

Saved $ 430K for caterpillar in tip/nozzle alignment and injector coking issue.

Ability to understand GD&T, DFMEA and DFM methodologies.

Experience in energy appraisal of manufacturing plants at Industrial Assessment Center, Bradley University, and Peoria, IL.

Self-starter, dependable, team oriented, dedicated to achieve high quality results and ability to work in multi-disciplined design team environment.

Technical Skills

CAD Packages: Pro Engineer Wild fire

CAE Packages: ABAQUS, ABAQUS Std., Pro/Mechanica

Energy Assessment Tools: PHAST, NxEAT and Motor Master 4.0.

PC Application: MS Office

Six Sigma Tool: Minitab

Education

Bradley University, Peoria, IL

Master of Science in Mechanical Engineering

Biju Patnaik University, Berhampur, India May1999-May2003

Bachelor of Technology in Mechanical Engineering

WORK EXPERIENCE:

Caterpillar Inc, Mossville, Illinois. Apr 2008-Till date

Engineer

Saved $ 90K for caterpillar in tip and nozzle alignment issue.

Saved $340K for caterpillar in injector coking issue.

Used Statistical Process Control techniques to resolve issues on a daily basis to improve first test pass of the product over 90%, thus leading to improved order to delivery to customer and reduced production cost

Worked as liaison between engineering and operations. Was a prime contact for all product related build and test issues on the injector manufacturing line

Lead cross-functional teams to resolve technical issues during production and implemented proposed corrective

actions by verification and validation of design changes and effective change management

Served as technical expert from the injector design team to identify root causes for the failures and managing a project plan to resolve issues in a fast paced environment

Executed design changes in Pro E, created detailed drawings and led through release process

Analyzed failures by conducting root cause analysis using 6Sigma techniques and various problem solving methods like the fishbone, DOE, 8D

Brainstormed concept designs, conducted Tolerance Stackups using GD&T principles

Lead team meetings to conduct supplier and manufacturing CPPD’s for selecting appropriate materials, machining and heat treat processes to meet product structural and functional B10 life time requirements

Functioned as subject matter expert to conducted Failure Mode and Effect Analysis (FMEA) for the injector

Coordinated with Structural analysts and Metallurgical Engineers to verify design structural and functional integrity

Devised test plans and coordinated with test engineering groups to schedule resources to validate product to meet DVVP&R requirements

Prepare and execute development test plan for performance, reliability and durability

Supplied instrumentation and performance test data to simulation groups to develop and validate simulation models for future analysis validations

Documented and presented validation and performance test results in team meetings

Documented all data required for full production level PPAP and released components in production

Implemented cost reduction ideas by modifying designs with minimum customer impact by meeting product costs & time lines

With a team of 6Sigma Black belts designed a process to investigate field returned injectors and report findings to the customer

Investigated issues like injector nozzle cavitations, coking and Engine power issues and made recommendations to fix the problems

Prediction of warranty costs to track warranty costs

Cummins Inc, Columbus, Indiana Jan 2008- Mar2008

Design Engineer

Performed Static and Modal analysis on Coolant plunger to verify whether it was able to withstand the pressure from the engine block.

Designed a new bracket for the Oil Pan to withstand lot of vibration and load from a pump.

Worked on leak test of a motor assembly in a lube system to check it is porosity.

Knowledge in NPID, EJR, Material Standards and Design Review Issue.

College of Engineering, Bradley University, IL

Prediction of Failure due to Crack Coalescence in Steam Generator Tubes Oct 2006 – Apr 2007

Performed Abaqus/standard analyses to find the Crack Coalescence Pressure in the steam generator tubes.

The elastic-plastic line spring elements are used to model the cracks, which are introduced by editing the input deck generated by ABAQUS/CAE to find the stress intensity factors.

ABAQUS/CAE is used for developing the model and the FE mesh and ABAQUS/STANDARD is used for the analysis

Industrial Assessment Center, Bradley University, Peoria, IL

Student Engineer Sep 2005 – Dec 2006

Lead a team of six members in energy making assessment report for BOMAG Americas, a compactor manufacturing company in Kewanee, IL

Performed 21 energy, productivity and waste assessment recommendations to improve energy efficiency, minimize waste and to improve productivity

Designed process layout for Stout Marketing to minimize manufacturing cycle time by thirty six hours a month

Analyzed facility and maintenance operations to ensure maximum productivity and efficiency while minimizing expenses by identifying plant floor layouts and routing of hardware.

Availability: Immediate

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