Engineer Manufacturing

SUDHANVA SANJAY KULKARNI

Email: *********@***.*** +1-313-***-****

https://www.linkedin.com/in/sudhanva-kulkarni

PROFESSIONAL EXPERIENCE

Project Specialist, Eberspächer North America, Inc Feb’19- Mar’19

Mentored project of FCA’s exhaust system

Assisted in launch of new production line

Optimize performance throughout production run by implementing Kaizen

Performing Preventative maintenance tasks as indicated on the appropriate TPM task list

Data input and recording for Continuous improvement

Process Improvement Lead, Volkswagen Group. Apr’17-Jul’17

Working with cross functional teams for calculating and improving the OEE or KPI by tracking downtime for 15 locations of AUDI A4 line and achieved a reduction in cycle time by 2 min

Implemented DFMEA, DVP&R, PPAP systems under VW standards for manufacturing

Assisted in internal audit and debugged automotive engineering drawings, Maintaining Data as per VW standards

Preparation of Weekly Maintenance schedule and Weekly Production Plan Report with implementation of attendance software in Volkswagen Plant which has made it easy to obtain records and has saved time

Recorded and observed the manufacturing processes and procedures for technical documentation

Manufacturing Engineer, Indian Biodiesel Corp. Ltd Sept’15-’May’16

To increase efficiency by 4 per cent of diesel fuel, development of appropriate percentage of palm fatty acid distillate which resulted in minimum emissions

Develop, maintain, process update and order fulfillment to support the production capabilities of biodiesel

Tested the biodiesel for its intended use and made sure it performs up to the manufacturers specifications

Presented detailed drawings, process sheets of biodiesel manufacturing process as a part of project

Project Engineer, Rucha Group Pvt.Ltd June’15- Jul’15

Performed Down-time Analysis of various manufacturing stations for Body in White (BIW)

Conceptualized Design of Fixture interpreting basic mechanical drawings used for engine mountings to achieve 7% faster and accurate installation with annual saving of 10,000$

Quality issues of suspension mounting were resolved resulting annual savings of 9000$ using “5 Why’s analysis”

Identified manufacturing defects by visiting suppliers and analyzing their raw materials

To support control plans, identified continuous improvement opportunities

Research Intern, Endurance Technologies Pvt.Ltd Nov’14 - Dec’14

Spearheaded resolution of quality issues of Aluminum High Pressure Die Casting manufacturing by Problem solving tools-PDCA and standardized manufacturing techniques for enhancing quality standards

Prepared Technical Delivery Condition Report using GD&T and got approvals from the head authorities

Estimated and compiled cost records of all subsystems and reduced the BOM cost by substituting design changes and directed the assembly for minimizing errors and time delays

COURSES AND PROJECTS

Formula Hybrid SAE Oct ’17-Current

Formula Hybrid SAE member, performing Finite Element Analysis of fuel tank and power trains using CAE

Material selection strategy of power-trains and fuel tank components for cost and weight effective design

Responsible for Project Deployment plan, Quality control, Generation of Cost Report and Sponsorship for SAE

Worked on the IC engine by dismantling, inspection, found reason for failure and provide corrective actions

Performed welding and sealed superficial cracks and grinded the deeper cracks to depth of vehicle body

Powertrains:

1.Studied internal combustion engines for automotive applications including the thermodynamics of power generation, component and subsystem requirements, analysis and test methods, evolving technologies

2.Worked on waste heat recovery method and employed in hybrid electric vehicles which offer significant benefits regarding the overall performance of the vehicle

Automotive control Systems:

1.Worked on input/output signal relationships in control systems using block diagrams and analysed control systems in time and frequency domains. Used MATLAB for checking stability of linear control system

2.Design of vehicle cruise control system model using MATLAB

3.Used Simulink for modelling four speed Automatic Transmission

Body Chassis:

1.Studied body structures configurations, primary vehicle motions loadings, structural analysis techniques modelling of automotive structures vibration analysis Fatigue (Structural Durability)

2.Designing vehicle bumper using Negative Poisson's ratio (NPR) material for Pedestrian Safety

Vehicle crashworthiness:

1.Understood the Federal Motor and Vehicle Safety Standards (FMVSS) and regulations of vehicle crash and safety. Quasi-static and high speed impact load cases that encompass front, side, rear, roof, and head impacts are studied

2.Presented paper on “Plastics and Composites in Automotive” under Vehicle Crashworthiness and Designed an axial crushing bumper tube and analyzed force deflection and energy plots using LS Dyna

Vehicle dynamics:

1.Study of Ride/Handling, Suspensions and Steering Systems, Brakes, Tires, Power Train and Aerodynamics.

2.Analyzed handling behavior of a vehicle using MS-Excel Solver

TECHNICAL SKILLS

CAD/CAE: Solid Works, ANSYS, AutoCAD.

Knowledge/experienced: LS-Dyna, MATLAB, GD&T, SIMULINK, CATIA and ETAS INCA

Engineering project management, Production planning and control, Supply chain, Root Cause Analysis, Failure Mode Effect Analysis, Cause and Effect Analysis, continuous improvement, 5-S, Lean manufacturing and Process Improvement

CERTIFICATION

Six Sigma - Green Belt issued by: Asian institute of quality management, accredited by ASCB (Europe) Limited

EDUCATION

Master of Science, Automotive Engineering August 2017-April 2019 Lawrence Technological University -Southfield, MI 48075, USA GPA: 3.8/4.0

Bachelor of Engineering, Mechanical Engineering August 2012-May 2016

University of Pune- Maharashtra, India GPA: 3.6/4.0

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