Injection Molding Mechanical Engineer

MAYANK BHARDWAJ

313-***-**** DETROIT, MI ****************@*****.*** https://www.linkedin.com/in/mayank-bhardwaj8/

Certified CREO & Lean Six Sigma Green Belt Mechanical Engineer with hands on experience in Product Design, Lean Manufacturing, Continuous Improvement and Process engineering.

TECHNICAL SKILLS

• PLASTIC INJECTION MOLDING • SPC • SOLIDWORKS • HYPERWORKS

• EXTRUSION • MOLDFLOW ANALYSIS • CREO • LS- DYNA

• PROJECT MANAGEMENT • CONTINUOUS IMPROVEMENT • AutoCAD • SIEMENS NX 11

• APQP, PPAP • MINITAB • SAP ERP • FANUC ROBOTS

PROFESSIONAL WORK EXPERIENCE

RESEARCH ASSISTANT – Wayne State University, Detroit, Michigan MAY 2019- Present

• Currently working Research Assistant for Wayne State University Robotics departments under Prof. Ana Djuric.

• Designed End of Arm Tooling using CATIA V5 for robot arm to help pick and place automation process.

• Programmed FANUC robots using VISION systems to automate process which could help in decreasing Cycle time and improve efficiency.

MANUFACTURING ENGINEER – Motherson Sumi Electric Wires, Noida, India JUNE 2015- JULY 2017

• Utilized Statistical Process Control (SPC) to analyze collected information and observations to determine production capabilities Cp, CpK

• Conducted DOE- Design of Experiments to find key process variables and utilized Root cause analysis for Injection molding process.

• Worked to optimize production to achieve Quality, Cost & Safety through the utilization of LEAN tools such as 5S, SMED, POKE-YOKE.

• Utilized LEAN manufacturing, Root Cause Analysis, TPM and found root cause for internal issues, quality rejections and failures.

• Responsible for improving processes through KAIZEN activities by providing tooling, methods to reduce cycle time and cost.

• Designed layout using AutoCAD for direct feeding of PVC to extrusion machines which helped company in cost-reduction of $100K.

• Led KAIZEN activities and performed design, tooling, equipment and processes and product changes to overcome production barriers.

• Analyzed capacity losses for bottlenecks using Key Performance Indicators (KPIs) OEE, PPM, Downtime, Cycle time.

• Designed 3D model and 2D drawings for EOAT(GRIPPER) using SOLIDWORKS and programmed FANUC robots to pick and place objects.

• Analyzed and planned work force utilization, space requirements and workflow also designed layout of equipment for maximum efficiency

• Maintained process documentation for PFMEA, Process Control Plans, flow charts as per existing standards.

MANUFACTURING QUALITY ENGINEERING INTERN - ONGC VIDESH, New Delhi, India JAN 2015- JUN 2015

• Analyzed drilling operations and reduced waste by 12.45% by analyzing workflow and Implementing Just-in-time production.

• Developed process Improvement and workflow layout changes to increase productivity by 14%.

ACADEMIC AND PROFESSIONAL PROJECTS

DESIGN, SIMULATION AND FEA ANALYSIS OF V6 ENGINE- Designed and modeled V6 engine parts using SOLIDWORKS and assembled parts in Siemens NX 11. Simulated the engine at 5000 rpm and performed FEA analysis using solver SOL 103 (Flexible body) in NX.

PICK AND PLACE OBJECT USING FANUC ROBOTS (FANUC LR MATE 200iD/7L) & VISION SYSTEMS- Created a program for Robotic arm to pick and place object with the help of catching gripper and used VISION systems to successfully automate the robot.

ANALYZED PROBLEM OF SHORT FILLING IN INJECTION MOLDING MACHINE- Developed chart for process input and output variables and used FISHBONE diagram to list causes. Conducted PFMEA to note RPN of causes. Recommended solutions like increase pressure and barrel temperature of zone 3. Used SPC to achieve process capability CP, CPK> 1.33 to ensure sustainability of the process.

TOYOTA RAV4 CRASH TEST USING LS-DYNA. - Modified material for critical members of vehicle from Steel to Aluminum alloy (AL 7075-T6), which resulted in weight reduction by 33.3%. Performed USNCAP full frontal, IIHS 40% Offset & reduced dash intrusion by 32%.

EDUCATION

MASTER OF SCIENCE - MECHANICAL ENGINEERING WAYNE STATE UNIVERSITY – DETROIT, MI AUG 2017-MAY 2019

BACHELOR OF TECH. – MECHANICAL ENGINEERING MAHARSHI DAYANAND UNIVERSITY – INDIA AUG 2012- MAY 2016

CERTIFICATIONS

• LEAN SIX SIGMA GREEN BELT •PTC CREO 2.0 (PRO-E) •SAP ERP •MINITAB

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