Engineer Design
Resume:
SUDHIR REDDY KALLU
***********@*****.***
Agile design Team Leader with 20+ years of experience in product development, project management and team leadership. Demonstrated motivational, passion, innovative, accountable, proficient at collaboration and proactively solve technical problems. Executed multiple projects by optimizing various sub-systems driving system integration. SKILLS & EXPERTISE
Design Failure Mode Effects Analysis (DFMEA)
Existing Product Improvements/Rapid Prototyping
New Product design
Strong Analytical Skills
Six Sigma Certification/ GD & T Knowledgeable
Injection Molding/Stamping/Casting and Forging design
Ability to Lead/Coach/Mentor/Work Cross-functionally
Excellent Communication skills/Presentations Skills/Problem Solving Skills
ProE/CREO 3D CAD modeling/Product Data Management
MS Office suite proficiency
PROFESSIONAL EXPERIENCE
Design Team Leader, Ground Engaging Tools (GET), Caterpillar Inc. (Jan, 2014-Jan, 2018)
Executed delivery of sub-system modules/engineering drawings while meeting required performance levels by managing projects and global engineering team resources. Drove reduction of drawing errors during 8 consecutive quarters as measured by the Corporate Auditing Team by providing leadership for global engineering design team. Delivered project/business metrics while reducing the program expenses by 5% using various tools and controls to manage schedule, cost estimates, financial tracking and reporting.
Delivered excellence in customer support. Acted as a single point of contact while taking ownership of Design Control. Led engineering drawing project management for the Hydraulic division business, which had a revenue of
$17.5M & part count of approximately 4,500. Successfully managed a large portfolio of sub-system modules/components and Technical Documents capturing engineering knowledge. Coached other engineers in technical guidance, performance standards and developed standard work and best practices to efficiently manage drawing releases. Aligned the drawing release process with customer requirements and improved efficiency and productivity throughout the entire lifecycle of the products.
Redesigned Ripper Shank Assembly to address a high-priority field issue. Successfully used Fishbone diagram for root cause analysis and implemented a well-validated production fix while improving machining tolerances and assembly operations. This effort resulted in reduction of warranty claims by $275K.
Developed a new patent pending precision dozer cutting edges that provide better penetration thru soil, optimized dozing performance, as well as 25% more wear capability along with 10% lesser weight than the competitive products. Optimized the design utilizing innovative ideas while working closely with cross-functional teams. Generated additional
$1.5M in aftermarket sales resulting in 5% increase in PINS by publishing new marketing documentation on these premium blades highlighting the benefits and competitive edge.
Led conversion of 400 Cutting edge models used on Graders, Dozers and Loaders from manual drawings to Pro-E 3D solid models. This resulted in generated additional sales of $500K in over 3 years’ period. Worked closely with supplier to continuously improve their manufacturing processes. Co-ordinated with overseas/contract/contingent resources for timely release of prints and set up new purchase orders with the procurement groups.
Submitted 6 Innovation Notification Forms (INF) for the team on new GET systems. By working with intellectual property patent filing legal team enabled the team to apply 3 out of 6 for US patents. . Design Engineer, Large Power Systems Division, Caterpillar Inc. (Oct, 2001-Jan, 2014)
Developed standardized work procedures, developed technical talent and taught the engineers’ both Team Center and CREO. Drove actions accordingly by communicating with GET engineering team while staying abreast with the Team Center revisions and updates. Improved Hydraulics team performance efficiency to 98% by developing standard work documents which ensured the team to work efficiently
Provided leadership in implementing a new Front Housing seal system as part of addressing quality issues and field failures. Using Six Sigma methodologies, reaped the benefits by reducing the quality defects to near zero while eliminating the field failures. Drove FMEA based validation and successfully used Pugh matrix to compare different designs.
Led continuous improvement programs for Tier 4 regulatory compliance of Turbo Oil lines on various machine models. This included investigating target attributes, conducting and leading effective design reviews with Machine Products groups. Scope included system design, risk assessments, acceptance testing and decision making along with focus on key performance indicators (KPIs). Managed global resources and assigned contract resources to complete 3-D modeling assignments on time. These efforts reduced the NPI costs by 8% yielding a savings of $1.5M just on one project.
Established a new strategy for Fuel transfer pump covers and hardware. Consolidated the parts offering from 8 to 2 on Machine engines by reviewing the product line offerings, optimized the portfolio for commonality which enabled a savings of about $500K/year just on 3 of the projects.
Resolved field failure issue of a very challenging turbo oil line leak on 3400 engines in mining application. Designed and implemented new prototype parts considering system technical requirements. Successfully validated performance using innovative test methods covering entire product lifecycle. Successfully met a very challenging cost goal to be within 2% of targeted cost. This production fix was also instrumental in reducing the warranty costs by additional $500K while delivering piece part cost reduction as well.
Redesigned Front Housing Assembly to address a high-priority field issue. Successfully used Fishbone diagram, impact stress FEA, sustainability and other analytical methods in determining the root cause and implemented a validated production fix. The effort also resulted in improved die-casting tolerance based on tolerance stack studies. The net result was lean product/manufacturing development leading to ease of assembly. This effort reduced annual warranty claims by $500K.
Developed engine Turbo oil lines for multiple engine platforms to support Tier4 emissions regulations. Designed oil lines, components and subsystems while meeting performance, cost, quality and demanding timeline requirements of a NPI program. Completed Design FMEAs on oil Lines and drove systematic validation using APQP process. Optimized the production designs, worked closely with Change Review Board and Supply management organization and delivered timely product launches. Developed Design guides for oil lines, which provided technical guidance for new engineers.
Delivered a validated Fuel pump design to address field failures on a high-volume production engine. Optimized design using engineering principles and testing methods, improved not only field performance by 10% but also delivered 15% higher output power. Optimized the geometry and features on a high-volume engine front housing to align with supplier machining processes and tooling changes. This cost effective solution resulted in $100K annual savings. Design Project Engineer, Butler Technical Group, Chillicothe, IL (Mar, 1998-Oct, 2001)
Managed and led multiple projects in Mechanical Design and Drafting. Led a team of engineers and assigned work flow aligning with the client’s requirements. Improved the team effectiveness and efficiency as evidenced from employee annual feedback survey. These efforts resulted in increased client satisfaction leading to additional business opportunities. Played a key role in developing policies in hiring new engineers. Coached new mechanical engineers and detailers in Pro-Engineer.
Managed numerous in-house design projects delivering models and drawings to Caterpillar for the Marine Engines. Also, led the verification efforts for in-house design & detailing of various Hydraulic parts and assemblies for Defense Products design plans.
Led the conversion of Electromechanical components including actuators, solenoids into 3D models while meeting demanding project time lines and successfully delivering the drawings in time and meet the project budgets at the same time.
Design Engineer, CDI Corporation, Peoria, IL (Mar, 1995-Feb, 1998)
Worked as design engineer with minimal supervision in OEM Solutions at Caterpillar. Redesigned mobile equipment’s Hydraulic lines to match with customer specifications. Supported design work and testing activities on Hydraulic lines, with a 30% increase in reliability in meeting the critical life goals.
Designed all purchased hydraulic and pneumatic components (i.e. valves, pumps). Provided technical interface with external hydraulic vendors and internal Supply Chain Management. Provided technical support to manufacturing and final assembly as it relates to hydraulic systems. Oversaw failure analysis of hydraulic and pneumatic components. EDUCATION
Master of Science in Mechanical Engineering: Portland State University, Portland, OR. (Jun, 1994) Bachelor of Technology in Mechanical Engineering: Sri Venkateshwara University, Tirupati, India. (Jun, 1989)
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