Engineering Engineer

SUMMARY

MS, ASE. Currently working at Ford Motor Company, Dearborn, MI April 2016 – Present.

Over a year of Research on Solid state Li-ion Battery Management Systems.

Over a year of hands on internships/ co-ops with engine and powertrain system maintenance and testing in OEM facilities. Testing & Validation of engine components and powertrain issues.

SAE involvement with Suspension Team- Braking material selection and component testing

Research projects in automotive integration and packaging.

System integration & Packaging

Hybrid Electric Powertrain Development

Benchmarking & GDT

B surface development and release.

Vehicle Interior, Power train system assembly & tear down.

Customer reviews, Quality assessment, Improvement & service.

Project Management and DFSS

3D Modeling Software’s: Auto CAD, CATIA, Pro/E, NX (Unigraphics), Solid Works.

TeamCenter Engineering, VSEM, FIP, WERS, PPAP, ASAP, PIM, PDP, DFMEA, FTA, DFM/DFA, DVP&R, ADV Plan, SPC, P-diagrams, DOE, MAT Lab, Dyno Testing, LabView, CANalyzer, CAN, OBD, Change Control, Minitab, Microsoft Office Suite.

Trained in High Voltage at UM-Dearborn as part of FSAE- Electric Team training

Can interview immediately

EDUCATION

University of Michigan - Dearborn 04/ 2017

Master of Science in Engineering

Major: Automotive Systems Engineering

G.P.A.: 3.4

J N Technological University Kakinada, INDIA 05/ 2014

Bachelor of Technology

Major: Mechanical Engineering

G.P.A.: 3.7

Relevant course work:

Core: Automobile: An Integrated System, Vehicle Packaging, Automotive manufacturing processes

Mechanical: Vehicle Dynamics, Automotive Powertrains, Noise Vibration & Harshness

Electrical: Hybrid Electric Vehicles, Vehicle Electronics, Automotive Sensors & Actuators

Management: Total Quality Management & Six Sigma, Project Management & Control

PROFESSIONAL EXPERIENCE

Ford Motor Company Dearborn, MI

Design & Release Engineer – Audio/Climate Control Modules & Finish Panels 01/2019 – To Date

Vehicle Launch Engineer (Integration) 04/2016 – 01/2019

Involved in Design & Release, Engineering Sign-off, interacting with the studio through A surface development and feasibility, development and execution of product verification plans & Testing.

Lead Program Specific FMA’s, SOW, RFQ Package Completion, BOM validation, Breadboards.

Design, Develop and Manage Module (RACM / APIM) Controller Area Network (CAN) arbitration, Signal Management, and Device Transmittal (DT) creation in Vehicle Software Electrical Management in Team Center Engineering.

Additional responsibilities of Interior Systems Engineering to develop ‘B’ surface across various vehicle programs and perform duties not limited to GD&T, DCR, ED&T, CNE- DF, AVBOM CMF, DVA, RSS analyses & Systems Integration.

Leading Interior & Exterior Appearance Excellence during launch to deliver Best-in-Class Fit & Finish and drive Component Engineering Sign-off and PPAP.

Work with cross functional teams to meet operations, R&D, and Quality to proactively ensure Vehicle subsystem and systems are manufactured right the first time to meet the business objectives related to quality and fit finish. Lead manufacturing process tuning and equipment troubleshooting to ensure product and vehicle system Craftsmanship objectives are met.

Succeeded in developing first-of-its-kind tracking system to achieve nominal specification targets from the supplier to greatly enhance fit & finish of vehicle interior before production Phase that was recognized by a FORD RECOGNITION AWARD.

Design Verification with GD&T and lead Product Sign off during Launch Phase DCV through Job 1 including Appearance, Design, Function and Supplier full PPAP.

Implementing six sigma Principals to find root cause for design failure and Making design corrections using CATIA V5.

Quality Projects (2): Performed Reverse Engineering and Implemented DFSS principles to resolve Design failures and delivered better than before interfaces to reduced Customer concerns.

Ford Motor Company Achievements and Recognitions

oRecognition and Achievement Team Award – December 2016

oEmployee of the Month – June 2017

oEmployee of the Moth – January 2018

oRecognition and Achievement Team Award – April 2018

oEmployee of the Month – December 2018

University of Michigan Dearborn, MI

Graduate Research Assistant (Full Time Work-Study) 10/2014 – 03/2016.

Research and development of Solid State Li-ion Batteries (SSB). Testing & Validation the battery’s capacity using EC Lab.

Calibrating the Batteries Management System for Optimal Performance at Wide range of operating conditions.

Achieved better capacity results by reducing the electrode thickness and introducing new test program techniques using design of experiments (DOE).

Implementing Design for Six Sigma (DFSS) to optimize the production & testing process hence, Maximized the productivity of the lab by over 30% in a span of 6 months.

Implementing Functional-FMEA to make sure ineffective procedures does not make it to the test bench.

Implementing design verification plan & report (DVP&R) for various Battery testing parameters used at different test conditions.

Successfully designed components using CATIA V5 with exact GD-T & produced reliable Test cells.

Inspecting, Interpreting, Analyzing the electrode materials and solid electrolyte sprayed with High Velocity Oxy-Fuel Flame using SEM (Scanning Electron Microscope), XRD (X-Ray Diffraction), and TEM (Transmission Electron Microscope)

Regularly Communicated Product development status to management and acquired funds for a full semester (Fall ’15- Winter ‘16).

PROJECTS & INTERNSHIPS

Member of Formula SAE- Electric at University of Michigan-Dearborn 09/2014-04/2015

Involvement with Suspension team- Braking material selection, Upright Design, Component Testing & validation.

Final car assembly, packaging & test runs.

Lucky Nissan, Andhra Pradesh., India 10/2013 - 02/2014

Engineering Trainee

Project in Engine Service and Maintenance

Inspection and testing of all the engine components.

Resolved faulty valve timing issues with the timing belt/chain check.

Kusalava Hyundai Pvt., Ltd. Andhra Pradesh., India 03/2013 - 07/2013

Intern (Vehicle Service Division)

Inspecting the vehicle powertrain, Interior & exterior.

Customer Interactions and support.

Diagnosed and troubleshot vehicle system defects using GDS VCI diagnostic tool (CANalyzer). Suggested replacement or service of different components.

VEM Technologies Pvt., Ltd. Telangana State., India 10/2012 - 02/2013 (Manufacturer of Aerospace equipment)

Intern (Production Department)

Inspected & conducted voltage Testes on Electric motors.

Ran Dynamometer tests to check for required output torque at a set RPM.

Liners India Limited. Andhra Pradesh., India 03/2012 - 07/2012

(Manufacturing of Cylinder Liners)

Intern (Production & Inspection Departments)

Managed the work flow for lathe, grinding, milling, boring & honing machines in the production lane.

Optimized the dimensions of metal chunks used for machining the cylinder lines.

Inspected of the cylinder liners for the required dimensional tolerances.

Played integral role in Production part approval process and reduced rejections by 15%.

JNT University, Kakinada 01/2014 – 05/2014

Fabrication of a working modal (vehicle) which uses multiple power sources (work published)

Designing of Multi Power to Single Drive Gear Box using CATIA V5

U of M- Dearborn: 09/2014 – 12/2016

Hybrid Electric Powertrain Systems

Developed MAT Lab scripts for computing the wheel force as a function of time for different driving cycles, to compute the state of charge (SOC) of a battery. Computed torque losses, power losses and efficiency of the motor. Simulated an EV & a series hybrid in different driving cycles.

Implemented strategies to Maximize Fuel Economy and performance of HEV/EV.

Analyzed system trade-offs between Engines & Batteries for developing a Hybrid vehicle.

Powertrain NVH- ICE/Electric Vehicles

Principles of mechanical vibration and acoustics.

Technology of electrical vehicles and hybrid vehicle and its associated noise and vibration issues.

Analytical skills of electrical and conventional vehicles key components such as motor, generator, engine, cooling fan, exhaust and intake.

Hands-on experience on noise and vibration testing and measurement including modal analysis, order tracking, sound intensity and material absorption measurements.

Vehicle Dynamics

Used CarSim HIL to simulate vehicle load transfer during acceleration and braking as part of course work.

Automotive Sensors and Actuators

Designed Failure Mode and Effect Analysis (DFMEA) for Actuators in Active Suspension System (technical paper) & Airbag deployment (group project)

Vehicle Packaging & Integration

Performed Quality function Deployment: Customer needs, benchmarking of interior package targets.

Occupant package design- Created new exterior and interior layouts for a 2020 modal vehicle using SAE standards and Performed Exterior and mechanical package analysis by Constructing interface matrix, interface diagram for the fuel systems.

Applied package evaluation techniques to the trunk area of sedan class vehicles and came up with cost effective methods to provide best in class trunk volume.

Developed Business plan and Systems Engineering Plan by performing Design validation, Process Validation, Evaluations, Design Reviews, Analysis and Testing for 2020 model year vehicle.

Automotive Manufacturing Processes

Paper: Alternative materials and manufacturing processes used for an automotive suspension system using composite materials like Glass Fiber Reinforced Plastics & carbon fibers and Manufacturing processes like resin transfer molding, filament winding (FW method) & Pultruding processes.

TQM & Design for Six Sigma

Worked on variability reduction and succeeded in reducing the production variability and standardized manufacturing process parameters.

Evaluated the process capability of SSB manufacturing by Statistical hysteresis testing and eliminated faulty practices.

Achieved better manufacturing process results and consolidated the work done in a span of two semesters.

Used control charts (X bar- R, X bar- S, C, U, P, np) to monitor and control the manufacturing process for better results.

Project Management & Control

Project planning, scheduling, systems development, APQR, PERT, CPM, Resource allocation & leveling, Customer research, cost estimation, Controlled & earned values, and risk analysis

Term Project: Contract for Advertising a Not for Profit Medical Research Centre to attract donors we have used all the above mentioned techniques for this projects management & control

Technical Paper: Research on Energy Efficient Active Suspension System with Vision.

PUBLICATION

“Fabrication of Dual Charged Low Emission Hyper Go-Kart” Yuva Engineers 05/2014

Electrified the power train in such a way that the IC engine is optimized for maximum efficiency

Link: http://www.ijmetmr.com/mayonline2014.pdf

CO-CURRICULAR AND COMMUNITY ACTIVITIES

Member of Formula SAE- Electric Team (Suspension) at University of Michigan- Dearborn 09/2014-4/2015

Volunteer: Alternative spring break- Manistique, MI from University of Michigan- Dearborn 02/2015

Volunteer: The North American international auto show- Detroit 01/2015

Benchmarking different vehicles for their attributes and specifications. Looking for “WOW” factors.

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