Engineer Design

KHAJA NAJMUDDIN

***** ********** ****, ***. #***, Farmington Hills, Michigan 48334

LinkedIn Profile: http://www.linkedin.com/in/khaja1najmuddin

248-***-**** (h) abnq0p@r.postjobfree.com 248-***-**** (c)

MECHANICAL ENGINEER

Inventive, results-driven design engineer with over six years experience in product design &

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development.

Proven record of performance that meets or exceeds expectations, directing engineering activity

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from concept to production to ensure customer performance requirements are met.

Collaborate successfully with cross-functional teams to incorporate Design for Manufacture

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(DFM), and value analysis/value engineering (VA/VE) ideas into design.

Recognized for creative development of innovative patent ideas.

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Experienced in CATIA V5 FEA simulation tool, part & product design and surface modeling.

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PROFESSIONAL EXPERIENCE

Senior Applications Engineer, Chassis Brakes Engineering Department

ROBERT BOSCH CORPORATION, Farmington Hills, MI 2008 – May’ 2009

Developed DV/PV plan, created timeline for validation testing, established surrogacy for similar design

and implemented supplier resource changes. Documented 8D reports by investigating root cause for

non conformance and failure.

Achieved expertise in using DRBFM to implement design changes, created awareness sheets, block

diagrams, change vs function matrix, 5 WHY charts and work sheets.

Performed design stacks and packaging studies, optimized design using CATIA V5 FEA simulation

and space analysis tools.

Senior Design Engineer, Foundation Brakes Engineering Department

AKEBONO CORPORATION, Farmington Hills, MI 2002 – 2008

Successfully lead the design and development of brake caliper from prototype to production. Performed

brake force and torque calculations based on customer’s band width parameters; coordinated with

manufacturing plant, suppliers and customers to optimize the design for stress, deflection,

manufacturability, assembly and conformance to specification. Enabled on-time kickoff of production

tooling by successfully releasing detailed layout of caliper assembly.

Determined applicability of value analysis/value engineering cost reduction ideas such as reduction in

lining thickness and change in material of components to address customer concerns.

Extensively worked on reviewing detailed 2D drawings and 3D model with strong insight in GD&T.

Successfully provided production support by taking over design responsibility from parent company in

Japan.

Lead a team of two engineers and three designers, releasing pad drawings for various aftermarket

applications and product lines. Organized design review meetings, developed workflow procedures and

schedule.

Experienced in SolidWorks with strong analytical skills, knowledge of manufacturing processes and

their tolerance capability such as casting, machining, cold forging, stamping and molding.

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Khaja Najmuddin Page Two

KEY ACCOMPLISHMENTS

Introduced and developed the following patent ideas for Advance Projects, earning a Memorandum of Invention

Award (MOI) for each:

BEAR-LOC INTEGRAL PARK BRAKE

Initiated concept of using interference fit locking device in rear integral caliper to replace lead screw

adjuster mechanism by using telescopic piston. Analytically proven to improve performance with fewer

parts compared to existing design.

HIGH FRICTION CLAMPING INTERFACE

Introduced the concept of using super elastic alloys to create high friction clamping interface between

piston and actuating mechanism. Improved efficiency by reducing the impact of parking mechanism to

service brake.

Developed mechanical product design solutions to address design issues encountered during design validation and

production phase:

Created design guideline for stiffness of housing in caliper assembly to minimize clamp load relaxation

from hot parking to ambient condition. Analyzed design guideline using DRBFM tool to determine risks

and trade offs in caliper performance.

Resolved bolt loosening and bolt fatigue failure issue experienced on vibration durability test by

establishing the root cause through analytical calculation.

Optimized the design of seal groove to maintain running clearance achieved through piston retraction.

Interpreted and analyzed tolerances to maintain hydraulic integrity of piston assembly.

Designed new rivet type wear indicator replacing clip-on wear indicator to withstand rugged handling of

parts at customer assembly plant. Feasibly designed to fit in the existing assembly with minimal impact to

tooling of other assembly components.

Investigated root cause of outer pad disengagement issue in caliper assembly, advising customer of

potential failure mode and counter measure. Implemented counter measure to improve detection rating in

DFMEA.

Effectively controlled load of lever return spring at installed and maximum load condition by designing

new jig, reviewed CPK results from plant to confirm tolerance on spring load.

Eliminated improper assembly of pads in brake assembly with cost-effective Poka-yoke solution.

Saved tooling costs on new applications by developing tool for friction shape consolidation, initiating

change request in change notice database for approval from plant, sales, and purchasing.

TECHNICAL COMPETENCIES

Design Tools: CATIA V5, SolidWorks, CoCreate, AutoCAD, Hypermesh.

Operating Systems: UNIX, MS-DOS, Windows NT/95/98/2000/XP

Applications: MS Word, Excel, Access, PowerPoint, Outlook

Training: Design Failure Mode and Effect Analysis (DFMEA)

Design Review Based on Failure Mode (DRBFM)

EDUCATION

Master of Science in Mechanical Engineering, Wayne State University, Detroit, MI; 2002

Bachelor of Science in Mechanical Engineering, Osmania University, Hyderabad, India; 1999

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