Product Development Engineer, Design Engineer

SAI SANTOSH KIRAN TEJA AKANA

Contact: +1-313-***-****, E-mail: ac5bm6@r.postjobfree.com, Add: 3204 Stuart Ln, Dearborn, MI – 48120.

SUMMARY

An enthusiastic Automobile Engineer having diversified expertise in the vehicle product development with a demonstrated ability in Vehicle Systems Integration, Ergonomics and Packaging

Efficiently handled the Product Development including requirement analysis, concept development, preliminary design, detailing, validation, prototyping and testing activities

Supervised process critical activities in Product Development including GD&T, DFMEA, DFMA, DVP&R & VA/VE

Expertise in CAD using Siemens NX and CATIA V5

Proficient in FEA methods using Ansys 17.0 and Hypermesh

Fluent in German language

EDUCATION

University of Michigan-Dearborn, MI, USA. Graduated - Dec 2017

Masters in Automotive Systems Engineering

Jawaharlal Nehru Technological University, INDIA. Graduated - May 2015

Bachelors in Mechanical Engineering

PROFESSIONAL EXPERIENCE

HYUNDAI MOTOR CO., INDIA. June,2014 – October,2015

Position: Seat Foam and Comfort Engineer

Functional areas:

Actively involved in Design Release, Quality Improvement, Supplier Integration, Prototyping, Testing and Validation of multiple systems

Good working knowledge of seat system components, Seat foam and Seat Head Restraints

Conducted Digital Pre-Assembly checks and signed off CAD/Drawings for Prototype and Production Intent Parts

As Total Quality Management, used to lead multi-functional teams for quality supervision and improvement by taking up VAVE analysis, DFMEA, PFMEA, Process control, QFD, Pugh Analysis, DFSS through DMADV/DMAIC and Statistical Process Control (SPC)

Interfaced with Finance and purchasing during cost approval forums and change control meetings

Responsible for providing quality oversight to the change management system for change controls related to filling process of Validation. This included providing plan creation oversight, verifying that changes adhere to SOPs and regulatory compliance

Involved in physical and dynamic simulations to comply with Hyundai design requirements and regulatory practices

Used Visual Mock up analysis to find and resolve form/fit/function design issues and rectify them in the early stages of designing

Managed AVBOM with respect to single commodity assemblies and complete system assemblies

Played an active role in successful documentation and implementation of PPAP and APQP requirements

Participated in engineering change control meetings to make sure all the quality requirements were meet

Product trail runs performed to analyze the pros and cons of the proposed engineering changes

Review of FMEA’S (DFMEA, PFEMA), control plans and SPC data to derive corrective and preventive actions.

Worked as a liaison between Hyundai and supplier group in discussing the technical issues and concerns with the products and preparing corrective actions for the same

METRO VALVE GUIDES, Hyderabad, INDIA May 2013 – May 2014

Position: Product Development Engineer

Designed and developed Valves, Valve guides for Internal Combustion Engines for compact cars segment, mid-size sedans and trucks using CATIA V5

Created Orthographic Projections and Isometric view drawings for the components

Responsible for Design release functions including CAD, FEA, GD&T, DFMEA and DFMA

Was part of multi-functional teams to perform VA/VE analysis as a part of Lean Engineering implementation

Hands-on experience with Enterprise Resource Planning and PPAP methodologies

Familiar with miniature features sub-millimeter in size, rather than sheet metal works or design for large machinery

Functional knowledge of Casting and various machining processes including CNC programming

METAWING Inc., INDIA Jan 2013 – March 2013

Project Intern

Participated in “Reverse engineering of an automobile engine” a technical internship, which was a nationwide event held in India

Was provided with opportunity of hands on training experience on Engines, Powertrains and transmission systems

Assembling of Internal Combustion Engines, Engine Management and using reverse engineering techniques

ACADEMIC PROJECTS

Vehicle Packaging and Ergonomics:

Using three different vehicles of a similar market segment performed Benchmarking analysis by selecting one as the reference vehicle, other two as competitors, all different packages were evaluated. Using the evaluations and feedback from the subjects, the new vehicle with more sophisticated package was designed

“Driver Package, Controls & Displays Evaluation”: Using Human factors evaluation on dimensions of interior package, locations of controls used on steering, driver door and instrument panel were evaluated by obtaining various results from the subjected drivers and passengers

“Evaluation of Entry/Egress and user convenience features”: Using subjective testing the tasks were performed to understand the errors/issues associated ergonomically and by conducting extensive task analysis in field of entry/egress, cargo loading/unloading. To evaluate the relevance of these convenience features, the methods observation, communication and experimentation were used

Conducted ergonomic evaluation of our Target Vehicle and made a new package with all the requirements accordingly with SAE standards, using JACK simulation tool.

Automotive assembling systems:

Redesigning the instrument cluster by analyzing the components and sub-components, Using Design for Assembly (DFA) and Design for Disassembly (DFD) the time consumed in assembling a part and disassembling were estimated. Based on the assembling time and design considerations, the part design was changed and the number of components used were reduced to decrease the assembling and process time

This helps in the reduction of parts used, using handling tables and precedence diagrams the assembling process is simplified, reducing the component and assembling cost. Hence, assembling time decreases and which helps in higher assembling efficiency

Vehicle Integration Engineering:

“Benchmarking and Preliminary Design Specifications”: Target vehicle for 2021 was chosen along with competitors for in detail benchmarking, and development of preliminary specifications of target vehicle

“QFD, Vehicle Attributes and Cascading Requirements”: Development of product specifications through the application of the Quality Function Deployment (QFD) and develop attributes to a selected vehicle system

“Vehicle System Analyses, Interfaces, Trade Offs”: Analyzing vehicle fuel system of target vehicle, developing vehicle level attribute design requirements and understanding interfaces between systems and discuss any trade-offs and issues

“Business Plan Development”: Creating a business plan for the 2021 target vehicle, estimating costs and revenues, sales projections, timings and gateways for the product development and discuss with senior management team

Automotive Manufacturing Process:

To Employ a new material and manufacturing process for manufacturing the components of an engine and show how it can be more efficient than the existing process and materials used

Alternative as well as new materials were proposed for the engine components. Different manufacturing processes were considered for obtaining better strength, durability of those components

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