Engineer Mechanical

Subhash Mamidi E-mail: *********@*****.***

Tel no: 440-***-**** (Cell)

Professional Summery

Mechanical Engineer with total 7+ years of experience in areas like product & Process

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Development, Cost reduction, Value Engineering, Tool Design, Vendor development, Tear-Down,

CAD/CAM, Plant Restructuring-Product Validation, Product Technical Support, Six Sigma, GD&T.

Last 5 years associated with GE Consumer and Industrial-Lighting – Satyam Computers as

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a Technology Design Engineer, executing NPI/CTO/Value engineering/MCTO (Product/Material

cost take out)

Good Experience in design of Ballast enclosures/Housings.

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One and half years of experience with John Deere & Fisher Controls - Onward Technologies

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as a Cad designer to generate 2d and 3d models of varies engine parts, Control valves and

Assemblies by using the softwares of Pro-e 2000 & Solid designer

One Year experience with Bajaj Tempo as Associated trainee and responsible for various Sheet

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metal dies design of Panel dies, compound dies of Tractor Components.

Certified Six sigma Green Belt at Satyam/GE C&I.

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Receipt of GD&T certification from Fisher Controls/Onward Technologies.

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Experience in Designing Ballast Enclosures/Housings for varies types of Products.

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In depth knowledge of Plastic and Sheet Metal Product design and Tool Design.

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Proven ability to apply Design for Six Sigma (DFSS) methodology and tools at various stages

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during project implementation of NPI and PCTO, cost reduction projects.

Strong analytical and problem solving skills developed through professional trainings and

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experience at Onward Technologies and Satyam Computers services/General Electric- Consumer

& Industrial.

Knowledge of Financials and budgetary control for NPI/PCTO/MCTO/ VE projects.

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Good experience on CAD software’s such as Pro/E 2000,wildfire – 5000hrs, AutoCAD – 2000hrs

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Solid designer/ME10 – 1000hrs, Intralink – 1000hrs.

Good knowledge of common-space/workspace, Check-in and Checkout of objects, Updating and

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synchronization of WS in Intralink.

Creation of Items, Item revisions, Data sets., Revising the IR’s, Establishing the process to Item,

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Releasing the items in e-CAD system Extensive usage of e-tools of GE like BCN, BCR, e-Cad.

Good Understanding of ISI, ANSI and IEC standards for lighting products.

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Educational Qualifications:

• Bachelors Degree (B.S.) in Mechanical Engineering from IME Mumbai, India

• Advance Diploma in Tool Design specialization in Plastic and Sheet metal designfrom Central

Institute of Tool Design, India

Work Experience

Satyam/GE Consumer & Industrial from Oct 2003 – Till Date

Design Engineer

Working at GE Lightings Technology division as a Design Engineer. Worked on various types of

projects such as New product Design and Development, Product and Material cost take out, Plant

restructuring-Product Validation and vendor development.

Key Activities performed:

Project scoping, Cost estimation, Feasibility Study, Concepts generation, Preparing test plans

(Product Validation plans), Design and detailing, Prototyping, Conducting DOE’s, Conducting Pilot

test/trial runs, Inspection and Testing, Statistical data analysis, Technical Reviews, Restructuring-

Product Validation, Project implementation and documentation related to project.

Projects Completed:

High watt e-HID Ballast enclosure:

• Successfully completed High watt e-HID NPI program and Product launched on schedule.

• One of the two mechanical engineers for the program

• Associated with the program from T1 review to till the production launch

• Activities-Design, CAD, developing installation and process instruction sheets, ePDM data

management

Ultra start T8 Ballast enclosure:

• Successful Mechanical design of ballast housing; product launched on schedule

• Only mechanical engineer for the program

• Associated with the program from T1 review to till the production launch

• Activities-Design, CAD, developing installation and process instruction sheets, data management

Low watt e-HID Ballast enclosure:

• Successful Mechanical design of ballast housing; product launched on schedule

• Only mechanical engineer for 20W, 39-70W and 70-150W low watt eHID

• Associated with the from T1 stage till the production launch

• Activities-Design, CAD, data management (ePDM)

D1 Igniter and D5 Ballast housings:

• Successfully launched the product with in the scheduled period.

• Design one-piece igniter module per D1S, Material selection for housing components that meet

tech. specification & cost targets

• Weight reduction to 65grams

• Package the all components within the given form factor

• Design holder for 25-30KV transformer

• Develop assembly process & audit igniter module contract manufacturing

• One piece igniter housing/components designed

• Weight reduction from 81grams to 65grams

• Aluminum metallization instead of having Alu. EMI shield

Responsibilities:

• Develop various conceptual designs to achieve product functional requirements.

• Presenting various technical aspects for the concepts developed to the higher management and

build confidence on the design.

• Development of 3D digital models to visualize the concept design.

• Identifying the best concept from the various components generated using six sigma

methodologies.

• Responsible for following Design for Six Sigma (DFSS), Design for Manufacturing (DFM), Design

for Assembly (DFA), and Design for serviceability processes during project execution.

• Development of Functional Block Diagrams (FBD) and Failure Mode Effects Analysis (FMEA) for

the best concepts identified.

• Identification of suppliers and obtain quotes to develop various components to prove feasibility

of the concept.

• Interaction with various suppliers and develop prototype samples.

• Validation of conceptual design functionality requirements.

• Responsible for testing and validation of the new design.

• Validate and verify prototype developed meets design specifications.

• Identification of assembly process for various components in the design.

• Release of component and assembly drawings for all the components in the design.

• Responsible for maintaining the product quality.

• Execute project to ensure cost reduction benefits, quality, six-sigma, service and reliability goals

are achieved.

Plastic Base for commercial Washer (Value Engineering Project)

The purpose of this effort is to convert the Metal Base assembly to a Plastic Base with no compromise

in quality and functional performance. In fact the new design has resulted in increased quality of the

washer product. This project has resulted in savings of ~750 K USD to washer business annually over

a production volume of 700 K units.

Responsibilities:

• Develop design plans & project schedules and manage project execution.

• Perform Tolerance analysis and develop Functional Block Diagram (FBD), Failure Mode effective

Analysis (FMEA), Parameter diagrams (P-diagram).

• Co-ordinate testing and validation of the new design for product evaluation.

• Analyzing various test data and summarize the results and present findings to the higher

management.

• Interaction with cross-functional teams, present findings at technical reviews and obtain

approvals for project execution.

• Co-ordinate with manufacturing, production engineers and participates in various trial builds and

production runs for the project.

• Analyze product quality through field data to assess product health and address technical issues

before the product reaches customer.

• Ensure design meets safety requirements and obtain safety approval for the project.

• Execute project using six sigma methodologies for cost benefits, improved quality, and improved

serviceability requirements.

• Use DFSS (Design for Six Sigma) and DFR (Design for Reliability) methodology to prove and

implement new and modified designs.

• Analyze quality issues through data analysis, field returns, and experimentation to create more

robust design to reduce service call rates.

• Root cause failures observed during testing and responsible for taking corrective action using

fault tree analysis (FTA).

Onward Technologies from April 2002 – Oct 2003

Application Engineer

Generate 3d Modeling of Plastic and Die Casting components.

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Developed the assemblies for control valves.

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Preparation of Bill of Materials

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Responsible for overseeing the Quality procedures related to the projects.

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Responsible for quality check for all the models

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Conducted Internal Trainings on Tool Design.

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Trained for GD&T

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Assistance to the Project Leader in doing the proper estimation for projects, planning the

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delivery dates, correspondence regarding technical queries, setting the milestones, developing

the expertise in team for fast execution of the project.

Bajaj Tempo from Aug 2000 – Aug 2001

Diploma Trainee

Tool Design of Panel dies, Compound Dies

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Manufacturing Follow up with Tool Room for the designed Dies

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Participating in Tool Tryouts

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