Manufacturing Engineer Sheet Metal

SAURABH RAVIKIRAN BAPAT

Milwaukee, Wisconsin - **227 559-***-**** **********@*****.***

OBJECTIVE

An Internationally Experienced Mechanical Engineer (Master of Science) having extensive knowledge of Medical Devices, Manufacturing Processes, Engineering Concepts and Designing with Effective Communication Skills. Presently working as a Manufacturing Engineer at GE Healthcare. Open to Full-Time Position in the Field of Manufacturing or similar.

TECHNICAL SKILLS

Documentation: EQ (IQ, OQ, PQ), ECR/ECO, Software Validation, Process Validation & Verification, PPC, BOM, and MSQ. Generating OMS, QPA, PDL, and Work Instructions.

Methodology: Six Sigma and Lean Manufacturing.

Quality Tools: 5Why, Fishbone Diagram, Product Life Cycle, DFA, DFM, DFMEA, PFMEA, DVP&R and DFSS.

Experience in GD&T, Bill of Material, Tool Design, Manufacturing and Assembly Method Knowledge (Injection Molding, Blow Molding, Sheet Metal Design, Snap Fit Design, Jigs & Fixtures, Vibration Welding).

In-Depth Knowledge of Automotive Engineering Principles.

SolidWorks 2016, CATIA v5, EM Works, AutoCAD 2016, FEMM, MATLAB and Simulink.

CAD modeling, Drafting, Dyna-Cam, FEA Analysis, MS Office.

C, C++, and Java – Basic Programming.

EXPERIENCE

Manufacturing Engineer, GE Healthcare., Milwaukee, WI. May 2017 - Present

Working on Process Qualification, Process Development, and Continuous Quality Improvement in an FDA regulated environment.

Expertise in Commissioning New Equipment like Milling & Grinding Machine, Optical Gaging Machine, and Wire-saw.

Working extensively on Software Validation, Process Validation, EQ (IQ, OQ, PQ) of new and existing Equipment.

Working on Engineering Change Control for Implementing Manufacturing Changes.

Experience in creating OMS, QPA, PDL, DMR, and DHR to ensure that Product, Equipment, Tools, Processes, Software, Training and Documentation meet requirements.

Expertise in Process Validation, Test Method Validation, Process Repeatability and Stability.

Working on Programming of Milling, Grinding, OGP, and Microwave Cure Machines.

Manufactured and Assembled CT Detector Parts like Cast Reflector, Ceramics, and Fencing Material.

Applied Six Sigma Techniques to Minimize the Error and Improve the Process Capability of the Line.

Applied Lean Manufacturing Techniques – PFMEA, DFM, Kaizen and 5 Why process to ensure the Cost-Effective Manufacturing Process.

Working on Sheet Metal processes like Stamping, Punching, Bending, Drawing, and Bending.

Working as a Lean Engineer on Reducing Cycle Time and ensure smooth flow of process throughout the line.

Manufacturing / Design Engineer, MeritOne Engineering Solutions, Farmington Hills, MI Sept 2016 – April 2017

Worked on Manufacturing, Automation of Process, Testing and Verification of Car Interiors.

Worked on Process Development for Automatic Car Assembly Robot.

Worked on Designing and Automation of Robotic Arm used for Painting the Plastic Product of Car Interiors.

Manufacturing and Development Knowledge of the Plastic Parts and Products, including Feasibility Studies, Class A Surfaces, Class B Attachments, and Drawings for Automotive Parts.

Worked on Troubleshooting, PV, EQ, and Automation of Plastic Injection Molding Equipment.

Manufacturing Engineer, ASB Steels Pvt. Ltd., Mumbai, India. June 2013 - July 2014

Applied Lean Manufacturing Techniques – PFMEA, DFM, Kaizen and 5 Why process to ensure the Cost-Effective Manufacturing Process.

Applied Six Sigma Techniques to Minimize the Error and Improve the Quality of Boilers and Heat Exchangers.

Manufactured and Assembled Different Sheet Metal Casings for Boilers, Heat Exchangers, and Condenser used for Air Conditioners.

Worked losel on Sheet Metal processes like Stamping, Punching, Bending, Drawing, and Bending.

Provided Technical Support and Assistance in Manufacturing Techniques and Handling Assembled Products.

Worked on Designing and Assembly of Heat Exchangers used in Chemical and Automobile Industries.

Worked with Quality and Maintenance Department for Design Approvals.

Mentored and Worked with Technicians in various Boiler Projects

Inspected Packing and Sealing of Steel Sheets, Boilers, and Furnaces.

Handled Inventory, Bill of Materials, and Shop Floor Management.

Designed various Components of Furnaces, Boilers, Casings, Boiler Exhaust System and Assembled Exhaust Systems Components along with Minor Detailing and Revision using AutoCAD.

Provided Technical Design support to Sales and Quality Engineering Departments.

Analyzed and Implemented Design for Manufacturing and Assembly Line Methods.

Biomedical Research Assistant, California State University, Fresno. Aug 2015 – Dec 2016

Worked on Designing, Modeling, and Controlling of a Biomedical Device – Prosthetic Leg.

Designed a Prosthetic Leg for the Lower Limb Amputees – SolidWorks.

Designed the outer casing of Prosthetic Components like – Shin, Thigh, and Ankle – CATIA V5

Designed a new type of Magnetorheological [MR] Fluid Knee Brake with a Non-Circular Rotor.

Modeled the movements of the Prosthetic Leg in MATLAB which included the Thigh, Shin and, Ankle Gait Cycles.

Used Multibody Kinematics and Dynamics Principles to determine the Torque and Positioning of the Leg using MATLAB.

Successfully Modeled the Braking Torque Equations of MR Knee in MATLAB for Controlling the Prosthetic Leg.

Conducted Torque Analysis of the MR Brake, using software like ANSYS, EM Works, and FEMM.

Manufactured the Biomedical Leg Prototype in house – All the Part and Assembly Operations.

PUBLICATIONS

Bapat, S., Nguyen T., and Wang, X., “Modeling of a Magnetorheological Fluid Knee in a Prosthetic Leg,”, Proceedings of the ASME 2016 International Mechanical Engineering Congress and Exposition (IMECE2016), Phoenix, Arizona, USA, November 11-17, 2016.

Bapat S., Nguyen T., and Suarez, A., “Design and Experimental Analysis of a Biomedical Prosthetic Knee with magnetorheological fluid,” Proceedings of the ASME 2015 Conference on Smart Materials, Adaptive Structures and Intelligent Systems (SMASIS), Colorado, USA, September 21-23, 2015.

Bapat, S., “Development of a Z- Path Conveyor”, University of Mumbai, Mumbai, India, 2013.

PROJECT / THESIS SUMMARY

Modeling and Controlling of a Magnetorheological (MR) Fluid Prosthetic Leg - Thesis May 2015 - Dec 2016

Successfully Designed a MR Knee Brake with Non-Circular Rotor.

Derived the Braking Torque Equation for the MR Knee Brake.

Modeled the Prosthetic Knee equation in MATLAB.

Conducted FEMM and EM Works Analysis on the MR Knee Brake to Predict the Theoretical Braking Torque.

Conducted Cost Analysis to Commercialize the Product.

Z – Path Conveyor May 2012 – May 2013

Manufactured a conveyor which covered 3 tracks (two horizontal and one vertical path) using CATIA V5.

Designed, Constructed and did Material Testing of the Conveyor, Frame, Cordial Chain, and Sprockets.

Fabricated and Tested the Conveyor to ensure Smoother Material Handling Operation.

Robotics

Designed and Developed a Robot which is Durable and Quick for Performing Industrial Tasks.

Implemented the Robot for Industrial Automation Processes to Maximize the Production and Reduce the Material Handling.

EDUCATION

Master of Science, Mechanical Engineering. Dec 2016

California State University, Fresno, USA. GPA: 3.51

Bachelor of Engineering, Mechanical Engineering. May 2013

University of Mumbai, Maharashtra, India. GPA: 3.60

ACTIVITIES

Technical Paper Presentations on Designing and Modeling of Biomedical Prosthetic Leg – Thigh, Knee, and Shin.

Solar Panels Installation Program with Grid Alternatives – Fresno (Hands-on experience).

Mechanical Technical Adviser, Technical Adviser of SSJCOE Committee 2012, 2013.

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