SAGAR KSHIRE

Located in MI, able to interview in person.

Able to freely travel domestically and internationally with some restrictions.

SUMMARY

3+ years of real-world experience in NPD and CPI of powertrain and transmission components with a Tier 1 supplier

MS in Mechanical Engineering, Wayne State University, 05/2017, 3.5 GPA

Designed and assembled Drivetrains for two-wheel drive 2WD and all-wheel drive 4WD for an OEM, performed FEA analysis on engine block and mounting

Hands on experience in design, assembly, CAE analysis on transmission components like drive shaft, transfer cases, propeller shaft, gear box casing and gear design, clutch system components, engine components like engine block, inlet and exhaust valves, clutch system components

Working knowledge in Automotive systems like Powertrain and transmission system, Engine system, cooling system

Supported NPD including design inputs, verification testing, risk management and design transfer activities of multiple complex projects for quality improvements

Participated in cross functional team and subgroups to review and brainstorm technical data and design, to benchmark process and to design and release updates

Computer/Technical Skills: MS Office, Solidworks, Unigraphics(NX), CAE tools, GD&T, DFMEA, DFSS, DVPR, Tolerance stack-up, VAVE, APQP process, customer-oriented approach, cost effective solutions, resolve field issues

Thought knowledge of manufacturing processes: casting, injection molding, stamping

Prior experience with SAE Collegiate Club working as a Design Engineer

Excellent written and verbal communication skills

EXPERIENCE

Integra Technologies 05/2018 – Ongoing

Design and Release Engineer

Working on internal design projects providing initial mechanical design support, 3D modeling and creation pf production drawings and maintenance of design data of velocity washers; established DFSS and DFMEA plans

Assisting in the preparation of design documents to ensure the design history file is maintained, working of Bill of material, and updating other design and risk analysis documents

Write, review product specifications, test protocol, manufacturing processes, quality control, risk management documents

Wayne State University 08/2017 – 04/2018

Design and Research Engineer

Worked on battery and motor design project conducted by an OEM and WSU on electric vehicle

Performed design and Testing on an Engine exhaust manifold prototype design for yield strength and Temperature gradient, using CEA and CFD analysis, improving the durability and warranty, package new design within the current vehicle layout

Performed basic calculations and system design analysis on exhaust system components

Oversaw the risk management program including creating risk management plans FMEA analysis, maintaining reports and files, provided quality engineering and reliability, including establishment of quality and design evaluation criteria

Fives Cinetic Automation, Farmington Hills, MI 09/2016 – 09/2017

Mechanical Engineer

Studied customer components, systems and created design modules of Driveline system for OEM using CAD and other necessary CAE tools.

Assisted in the design, development, test, and release of drivetrain system and components to meet customer requirements and specifications for two-wheel drivetrain and four-wheel drivetrain system

Performed component and system level CAE, CFD analysis and performance-based calculations.

FEA analysis on rear axle for 2WD and 4WD assemblies and differential casing and gear assembly

Fixture design for an engine block mounting, testing of exhaust systems, and assembly of critical automotive components; Developed, tested, and evaluated theoretical designs

Managed development plans for respective program performing DFMEA analysis, performed drawing changes and periodic reviews, maintained BOMs, prepared design documents to ensure the design history file is maintained and recorded approvals for test protocols, and maintenance release of drivetrain system

Performed DFMEA and DFSS on fixture design for rear axle drive system and engine mounting, performed weight reduction of various powertrain components, improving the durability and warranty, package new design within the current vehicle layout

Knowledge in GD&T, DFMEA, DVP, DFSS, Tolerance stack-up analysis, Management of BOM

Utilized Solidworks, AutoCAD, UGNX, Team Center

Summit Engineers and Consultant, Nashik, India 06/2014 – 07/2015

Design Engineer

Worked as a New product development engineer for Japanese SUV automaker with Powertrain system design and frame (Chassis) design using UGNX

Applied basic knowledge of engineer principles and practices to task executed in the development, analysis, release of axle design and subsystems of powertrain transmission through product life cycle

Oversaw the risk management program including creating risk management plans FMEA analysis, maintaining reports and files, provided quality engineering and reliability inputs to drivetrain design project, including establishment of quality and design evaluation criteria

Designed and CAE analyzed various peripheral components of driveline system like driveshafts, propeller shaft, intermediate shaft, universal joint, reinforcement of structural components, design and CFD analysis of driveshaft using UGNX

Fixture design for an engine block mounting and assembly of critical automotive components; Developed, tested, and evaluated theoretical designs

Worked on casting components like Clutch Box housing, Gear Box housing, Axle support

Designed and developed customer-oriented machines and components for automotive industry

Benchmarking, Brainstorming concept designs, Manual Design calculation, Selection of suitable design

Eaton Industrial Systems, Nashik, India 01/2013 – 12/2013

Intern Mechanical Engineer

Studied and redesigned an electrical line layout of the plant

23% productivity improvement of the plant by applying industrial tools like time and work study methods

Worked with Stem design and grain structure confirmation team for Exhaust and Inlet valves of Cummins and Indian Railways with 3D software Pro-E

Combined methodology for efficient improvement in productivity with work study and lean principles

Worked on lean tools, work study, SUR (Set Up Time Reduction) for better utilization of operator’s time

Studied and provided effective solutions for sheet metal and casting process as well as extrusion.

Improved efficiency of the plant by 32% and reduced overall waste of the plant by implementing different tools

7 wastes, TPM, AutoCAD, MUDA, KPI, Pro-E

Society of Automotive Engineers INDIA BAJA 12/2010 – 07/2012

Project Manager

Task -To design, build, test, promote & race an off-road vehicle that will survive the severe challenges of rough terrain.

Worked on CAE and CFD analysis of Powertrain components, mainly engine block and drive train

Worked on SAE standards helping to ensure safety, quality, and effectiveness of products

Assembled and manufactured an ATV under several strictly enforced standards of fabrication, repairing and medications of ATV, engine mounting and assembly, design, safety, ergonomics, aesthetics

Studied series of stringent static & dynamic test which included acceleration, maneuverability, hill climb, endurance events

Worked on FEA analysis, Solidworks, UGNX, AutoCAD, Stress-Strain analysis, Heat treatment and grain analysis treatment

PROJECTS

Finite Element Analysis

Full frontal, Side &Roof crash analysis of a car & truck including Airbag & Dummy using LS-Dyna.

Integrated FEA into CAD design, analyzed problems of huge sizes, multi scale analysis, multi physics analysis

Predicted and designed how a product reacts to real word forces, vibrations, impact, fluids, other physical effects. Worked on boundary conditions, interface analysis and FMEA

Accurate representation of complex geometry, Inclusion of dissimilar material properties, Easy representation of total solution, Capture of local effects, Boundary conditions, Algebraic Equations

Fatigue, Contact, Press-fit & Thermal analysis on various components using Hyper mesh & Abaqus

Productivity Improvement: (Lean Deployment tools & Work Study Methods) (Paper Published)

Combined methodology for efficient improvement in productivity with work study and lean principles

Improved overall performance and quality of a process with the complete assurance of larger annual profit margin

5s, wastes(Muda), Time and work study, Set up time reduction(SUR), Standard Work(SDW)

Cot-chamfering machine: (Redesign and manufacturing) (Paper Published)

Resigned and manufactured automated and system integrated SPM with help of data obtained through research and development provided by R&D

Variations in the sizes of rubber cot can be compensated and achieved successfully by the automated and system integrated machine

Chamfering, rubber cot, SPM, Catia V5, Poka-Yoke, FEA Tools

EDUCATION

Wayne State University, Detroit, MI 05/2017

Master of Science in Mechanical Engineering – CGPA 3.5

Pune University, India 06/2014

Bachelor of Engineering in Mechanical Engineering – CGPA 3.5

CAERIFICATION

Unigraphics NX 8.0 Basic aand Advanced Design

Pune University – German Language Level A1 Certification

RELATED COURSEWORK

Finite Element Analysis

Mechanics: Composite Materials

Manufacturing Processing Mechanics

Automotive Manufacturing System/Processes

Lean Product Development

Crashworthiness/Occupant Safety

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