Engineer Design

Avinash P Deshpande

**** *** **** *******.*********@*****.***

Normal, IL 61761 Phone: 316-***-****

Objective: Seeking challenging position as a Product design and development Engineer in a growth oriented

organization utilizing proven skills in computer aided design and analysis.

Profile:

• Experienced Product Design Engineer with strong modeling skills. Experienced in Plastic Injection

Molding, Die-Casting, Surface modeling, Sheetmetal, Engineering analysis, manufacturing processes, &

test engineering

• 8 years experience of Mechanical design & development at Caterpillar Inc. working on Motor Grader

products.

• Highly effective working in deadline environments, resolving production problems and minimizing stop-

ship times thereby increasing profit margins

• Signature strength in working with teams, consistently complete difficult assignments with minimal

direction and supervision. Uses seasoned judgment, design skills and production expertise to deliver

results.

• 8 years experience with Pro/E and Teamcenter. Extensive knowledge of GD&T in drawings, in accordance

with industry standards. (ASME Y14.5, AMSE Y14.34)

• Extensive knowledge of Fluid Dynamic Analysis and Finite Element Analysis.

• 6 Sigma Green Belt deployed the Six Sigma tools in all phases of Product Development Cycle of the

product.

Work Experience:

Engineer Caterpillar Inc., Decatur, IL Feb 2008-

Present

Senior NPI Lead in the Hydraulics team, core responsibility in this role is to deliver a robust hydraulic system to

our internal customer based on a set of functional requirements.

• Equipment Design: Utilized Pro E and other CAD tools to design highly customized parts handling for

motor grader hydraulic components. Developed manufacturing drawings. Performed stress, and tolerance

analyses on new designs conform to product specifications.

• Designed and develop casting for Electro-Hydraulic steering valve used on the Motor Graders Tier IV final

machines, led suppliers to make quick process changes to reduce cost and weight of component. Duties

included concept development, front-end Pro-E assembly layout using a skeleton and master model, and

design refinement based on prototyping and simulation results.

• Led NPI project that delivered structural castings for valve models used on motor grader models. Decision

making to select optimum materials, improved product life performance through designs that meet

customer life expectations and align with business strategy.

• Designed and developed Roto molded plastic hydraulic tank used on the Motor Graders Tier IV final

machines, Duties included concept development, front-end Pro-E assembly layout using a skeleton and

master model and design refinement based on prototyping and simulation results.

• Analytical and virtual design work- Developed control valve simulation models using Dynasty software

and used lab data to validate these models. Extensively involved in flow analysis using Fluent (CFD

software).

• Extensively involved with all validation/testing activities including FEA Analysis (Load, Dynasty &

Bolted Joint Analysis), Product field testing and On-Machine Stress Analysis.

• Cost and Yield Management: Proactively identified and recommended alternate suppliers and / or sources

to reduce program costs and increase profit margins. Worked closely with hydraulic pump vendor to

determine root cause of low yield, making recommendations that increased yield by 15%.

• Material Cost Tracking: Tracked direct material costs, provided explanations for variations, reported to

core team, made recommendations, monitored quotes from vendors and updated cost estimates as program

design matured.

• Managed design changes to meet the SAP system integration. Managed manufacturing and supplier quality

issues.

• Production Support: Provided engineering support by rapidly resolving all mechanical problems for

assigned programs in production.

• Leadership: Mentored new engineers enabling quick ramp up to manage Caterpillar design and process

standards. Developed spreadsheet tracking tool requirements and release schedule for new programs.

• Developed engineering specifications, design verification test plans for hydraulic systems and

electromechanical modules/components. Responsible for utilizing product engineering processes such as

DFMEA and documentation methods (DVP&R)

Senior Associate Engineer Volt Services at Caterpillar, Decatur, IL Dec 2005- Feb

2008

• Design Corrections: Designed articulation cylinders for K series tier III platform motor grader machines.

The new design resolved issue concerning piston to rod bolt loosening due to excessive articulation forces.

• Initiated engineering change process to resolve design conflicts in a timely manner. Utilize various internal

release tools (Teamcenter, DFX, Workflow) to complete projects.

• Design 3D manifolds from Hydraulic Schematic, optimized for cost by reducing size and machining

operations. Supported the Production Valve Stream Team for Manifold. Performed project milestone

scheduling and resource management for multiple programs. Concept development for insert-molded die

castings to allow housings to span multiple product line

• Provided adequate Hystat Systems on AWD feature motor graders for end-user. Collaborated with hystat

system suppliers to obtain new parts.

• Advised drafting personnel to create new drawings and revise existing drawings. Created bill of material

(BOM). Maintain accuracy and completeness to obtain all necessary parts.

• Respond to ‘Special Quotations’ by analyzing custom hydraulic configuration. Estimated time and

engineering work involved to release product change.

• Responsible for overseeing the overall mechanical design and assembly methods applied, to ensure that the

product is ready for production.

• Coordinated and supervised engineering work with Cat Brazil along with assisting Line Support Engineers

by resolving manufacturing issues caused on the assembly line.

Six Sigma Experience:

Lead Engineer on several six sigma projects at Caterpillar Inc. resulting in significant improvements in product

design, and reduction of product warranty cost.

• Lead Hydraulics engineer on a project to resolve steering component failures on North America Tier III

Motor Graders. Analyzed field failure data and developed test plan. Performed root cause analysis,

presented data to Product group. Implemented an improved design which helped realize savings in the

order of $1.1million in warranty costs.

• Lead Hydraulics engineer on Cold Start project to reduce machine parasitic at start up for North America

140M/160M/120M tier III platform Motor Grader machines. Delivered a new design in a quick and timely

manner. The designs provided great margins and generated annual revenues of $850,000 dollars.

• Lead engineer on the Fan motor case drain project for 16M tier III platform North America motor grader

machines for resolution to the fan motor shaft seal leak. New improved design of shaft seal saved $600,000

in warranty cost and improved customer confidence.

Design Engineer ATSI Services at CNH, Wichita, KS May 2005- Dec

2005

• Designer on engine project to reduce the throttle vibration of a Case (410/420) skid steer loader 3 cylinder

naturally aspirated engine.

• Worked on casted yoke cost reduction for New Holland track loader. Converted the yoke from sheet metal

to casting for reliability, resulting in reduced cost of $55.00 per part.

• Designed muffler mounts to prevent oil leakage between the head and mount of the engine for Case 420

skid steer. Reduced component costs by changing design, manufacturing processes and materials.

• Engineered tasks involving design, fabrication, validation and manufacture of assemblies, systems,

processes.

Graduate Research Assistant NIAR, Wichita State University, Kansas Sep 2003- May

2005

• Worked on composite panels to determine the fatigue properties and strength to identify the failure causes

of the composite panels.

• Contributed to setting up test fixtures in the lab for compression tests on honeycomb composite structures.

• ‘Machining as a high strain rate test’ - High strain rate testing of material behavior to provide useful

information for applications such as machining, forging, punching. Machining was carried out at various

speeds over a wide temperature range to study the effect of strain rate and testing temperature on the

mechanical properties in a systematic manner.

Design Engineer Cadem Technologies, Bangalore, India Aug 2002-Jun

2003

• Created CAD models and mechanical systems using Pro Engineer, created new concepts and approaches to

the design/development of new products, processes, and equipment.

• Worked closely with customer representatives and product development group to understand the

requirements and to achieve robustness and accuracy of complex functionalities in real life problems.

• Performed static stress analysis on various design of structural elements of machines using FEA tool

ANSYS to ensure the integrity and maintain high standards of quality.

Skills:

CAD: Pro/Engineer (Wildfire), Solidworks, AutoCad, Catia

FEA Solvers: Pro/Mechanica, FLUENT, Dynasty, Nastran, LS-DYNA

Other Software’s: MATLAB, Teamcenter, Simulink, DATK

Education:

MS in Mechanical Engineering Wichita State University, Wichita, KS GPA: 3.50/4.0 May 2005

BS in Mechanical Engineering Bangalore University, INDIA GPA: 3.65/4.0 Dec 2001

Academic Projects:

• Finite Element study of energy absorption in aluminum corrugated panels ( M.S Thesis Project): FEA

model of an aluminum corrugated beam was built in Patran and the analysis was performed using LS-

DYNA. The principal goal was to compare the energy absorption values of a 60 and 90 degree corrugated

beams from the FE analysis to experimental study. An optimal design curve was formulated based on the

comparative study for varying angle layups of corrugated beams.

• Bulkhead Analysis using Ansys: Aluminum bulkhead was modeled in ANSYS and material properties

were assigned. Stiffness was calculated using ANSYS by applying force at two points where head comes

in contact with the bulkhead.

• Study of Wear Patterns and effects of Surface Finish in Milling Inserts ( Senior Project): The project was

focused on developing an understanding of wear mechanism of cemented carbide tools milling.

Experiments were carried out onTN35M grade inserts using HMT milling machine and their wear

characteristics were determined.

Relevant Coursework:

Computer Aided Analysis of Mechanical Systems, Advanced Finite element analysis, Vibration Analysis,

Advanced Mechanics of Materials, Analysis of Manufacturing Processes, Impact dynamics, Design of

experiment.

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