KRISHAN KUMAR

acs9yr@r.postjobfree.com

980-***-****

Krishan Kumar is mechanical engineering professional with 10+ years of experience in automotive and manufacturing industries. He has outstanding background in engine performance, calibration, engine control, testing, emission control, data analysis, product design, planning timeline and cost estimation, research & development, quality control, production/manufacturing, data presentation, documentation and reporting.

He worked as Product Development Engineer (dyno test cell) at John Deere for three years with focus on aftertreatment parts design, performance and emission control of high power JD tractor diesel engines to meet Final Tier 4 (FT4) emission requirement per EPA regulations. Thereafter, he got opportunity to work as Performance Engineer at Caterpillar with majority of work on engine and aftertreatment parts performance, modelling and simulation using Matlab and Dynasty software tools. Later, he is worked as Engine Control Engineer at General Electric Transportation System (GETS Locomotive) Erie PA and currently working as aircraft Engine Calibration & Control Engineer at Lycoming Engines at Williamsport PA.

Professional Experience:

Engine Calibration Engineer Aug 2015-Current

Textron Aviation/Lycoming Engines, Williamsport PA

Working as Engine Calibration Engineer for ECU controlled single, four and six cylinders aircraft engines used for civil aviation @ Lycoming Engines which is a subsidiary of Textron Aviations.

Concept design for new ECU software and hardware requirements, documentation for Software Architecture & Design, software codes, and design validation test, Customer Acceptance Test, engine performance tests, Hardware and Software in link tests (HIL/SIL).

Worked closely with lab technicians, test and calibration engineers, and software and cross functional team to develop ECU software.

Develop engine calibration plan and schedules for new customized engine products and tune existing calibrations for existing engines to meet engine performance and fuel economy requirements at different speeds, altitudes and loads conditions to meet customers and FAA certification requirements.

Worked on CAN communication and protocols tools like Vector, KVaser, and ATI Vision hub, for communicating engine and ECU using microcontrollers and actuator’s control logics PLC.

Performed engine certification tests on both electronically controlled aircraft engines and legacy mechanical engines using SmartFyler, ATV Vision and Labview tools for data acquisition & engine calibration. Review test results with seniors and make necessary changes & upgradation in design and test procedures to meet the new customer requirements.

Solved any issue by following technical procedures, techniques, instrumentations and root cause & analysis and value engineering for product improvements based upon test results.

Skilled with Matlab algorithm and Simulink modelling for application software coding and implementation, Software Design Validation, Software and Hardware Testing, Engine Testing and optimize engine calibration

The calibration effort includes designing calibration values and maps that control engines to meet performance requirements, resulting in meeting customer needs.

Worked with cross functional research & development, verification & validation, production, and quality control teams to setup engine/dyno test cells and flight stands to run Avo Gasoline engines.

Coordinate different meeting for project status, new development or achievement, test result sharing, new techniques and brain storming sessions. Data analysis, data review & reporting for management level decisions.

Engine Control Engineer Oct2014-Aug 2015

GE Transportation, Erie PA

Working as Engine Control Engineer for Tier 0, Tier 1, Tier 2 and Tier 3 high power locomotive engine @ GE Transportation.

Worked on UP FDL Dash 9 and AC 4400 locomotive project to design, create test plan, validation testing using spin stand and locomotive, root cause and effects analysis and modify control strategies to address nuisance faults of Low Oil Pressure, Low Water Pressure, High Manifold Temperature and Hot Engine nuisance faults.

Worked on TE10/TE8 Yakutia/TMH 7FDL-12 cylinder loco projects for concept design, validation testing on spin stand/loco, data analysis and reporting, FDR design reviews closing to meet GOST emission requirements. Responsible for different ITR and FDR design review with principal engineer for high level implementation decisions.

Worked on Cold Engine Strategy and unstable rail pressure for KoRail locomotive and hence resolve issues using DFMEA to avoid field failure of software and hardware components.

Worked on Tier1&2 ECU/EMS project to identify specific parameters and change their threshold limits in matlab and C++ hand codes to get desired output.. Worked closely with software team for the changes to be made in hand code files. Used IBM Rational Clearcase tool to create new software change number (SCN) request and upload all details.

Hardware-In-Loop (HIL) validation testing of ECU and EMS software using SIM lab, modify Matlab Simulink models. Implemented the updated software on locomotive ECU & EMS and perform static and dynamic testing.

Hands on loco and spin stand Hardware-In-Loop (HIL) software validation testing for Crank sensor swap using test/decade box, CPU utilization, Firing sequence and skip fire tests using oscilloscope and picoscope, Low oil pressure, low coolant pressure, mode control, pump mapping, pop test, under/over rail pressure, gross horse power, coolant level sensor, crank pressure sensor etc; along with setting & handling different instrumentation and smart display.

Data acquisition using IDS/Hyperterminal/Canalyzer, data analysis using matlab and MS office, data management using History Tool/GE libraries/Salesforce and data/report presentation to team for peer review.

Design review process for generation of BOM, electrical schematics, implementing software algorithms, defining communication protocols, and validation testing.

Worked closely with Product Managers, Program Managers, Compliance Managers, Fleet Managers and Solution Architects in delivering products and features for global product line.

Performance Engineer April 2014-Oct2014

Caterpillar, Peoria IL

Worked as Performance/Simulation Engineer with Engine Performance & Afterteatment Calibration team @ Tech Center Catrepillar for large power mine and marine diesel engines & aftertreatment devices.

Data analysis of transient and steady state RMC cycles for mine and marine diesel engines.

Comparative analysis of simulated lab & field data.

Iterative simulation by changing convective heat transfer coefficient, mass of pipeline etc to minimize error and develop corrected Simulink Model.

Comprehensive 3D maps generation for exhaust temperature, flow rate, NOx, HC emissions vs. speed & torque at different test conditions. .

Technical discussion with test engineers for developing test matrix, hardware and instrumentation. Root Cause and effect analysis for discrepancy in test and simulated data

Create and modify Matlab script for thermal models and ECU AT to prepare dll files for developing thermal model, ECM and HIL models. Hardware-In-Loop (HIL), Model-In-Loop (MIL) testing of the updated model.

Software tools skills: Matlab Simulink, Dynasty, DATK for data processing, iSight for optimization, MS Office etc.

Product Development Engineer June 2011-April 2014

John Deere, Waterloo IA

Product Development Engineer in Advanced Power Systems Engineering (APSE) group @ John Deere. Managed different test cells equipped with high power diesel engines, aftertreatment devices and emission control instruments.

Develop, optimize, and calibrate exhaust systems for diesel engine test cells to meet off-road Final Tier 4 (FT4) emission regulations for high power diesel engines of 4.5L, 6.8L and 9L capacity.

Performance testing of different IT4, FT4 and Post FT4 after-treatment prototype devices like Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), Selective Catalyst Reduction (SCR), Ammonia Oxidation Catalyst (AOC), Exhaust Gas Recirculation (EGR), Turbocharger, Urea Quality Sensors, DEF dosers, decomp tubes and mixers etc.

Close loop engine and aftertreatment parts calibration for emission control of HC, NOx and PM with the usage of Horriba Mexa Bench, AVL FTIR and different electrochemical sensors.

Performance testing of different urea quality sensors to measure urea concentration and ability to detect different fluids/contaminates at different temperature.

Worked with suppliers on product design, product improvement, ordering and scheduling, product cost, price negotiations and total project cost. Used SAP Business suite, PDM, PDI and MASA tools.

Worked with vendors on different projects for ATD parts performance testing and shared test results, project cost analysis, cost calculation and maintain budget limits.

Technical discussion and support with other team members and groups for any test cell issue and resolve the same by using root cause analysis.

Managed three engine test cells and supervised different test cell operators for the daily activities and handled technical issues & improvements.

Worked on issues related with turbocharger actuator & valve, solenoid, EGR actuator & valve, sensors failure, DPF plugging, CAN and ECU software.

Worked on Opcode software files, config files, end of line and playfile on Lab Task Manager, and Engine Control Software including Matlab and GT Power.

Supervised test cell operators and technicians for various test cell related activities and work allocation. Worked closely with cost analysis team to have budget and cost estimations for different and project.

Data acquisition and management using Morphee, Test Manager, Lab Task Manager (LTM); Data analysis using DIAdem National Instruments, GT Power, Matlab simulation, CAN Communication and protocols, MS office etc.

Presentation of test data and reports to team members, management, vendors and suppliers.

Graduate Assistant Aug 2010-May 2011

Auburn University, Auburn AL

Project: Accelerated thermal stress testing of electronics packages used in automobiles and airplanes for reliability qualification.

Designed and conducted Accelerated Thermal Cycling (ATC), Isothermal Aging and Board-Level JEDEC Drop tests for range of BGA components with various Pb-free SAC solder alloy interconnects to investigate Failure Mode Effects and Analysis (FMEA) using Scanning Electron Microscopy.

Conducted material characterization tests to study the creep behavior and compare the relative performance of various Lead-free and mixed formulation solders for thermal applications.

Conducted dual thermal cycling test on SAC 305, BGA packages to interrogate damage superposition in multiple thermal environments.

Graduate Assistant May 2008- Aug 2009

Wayne State University, Detroit MI

Project: Effect of ion current on diesel engine performance & emission.

Setup single cylinder Hatz engine coupled with hydraulic dynometer and related instrumentation.

Perform engine calibration to achieve engine performance and emission requirement using aftertreatment parts to target NOx, HC, COx emission requirements.

Machined cylinder head to accommodate cylinder pressure sensor, and upgraded glow plug to accomodate ion probe.

Calibration of Pressure Transducers, Thermocouples, NOx machine and Dynamometer.

Performed different tests to study effect of fuel/air injection timing & duration and spark advancement on maximum power and fuel consumption.

Hands on dismantling and replacing engine cylinder, piston, piston rings, valves, rocker and lift arms etc.

Used AutoCAD and ProE tools to designed exhaust pipes, elbow tubes and other instrumentation.

Manufacturing Engineer June 1995 –Aug 2003

Sudhir Automotive, India

Sudhir Automotive manufactures precision fasteners like nut, bolts, shoulder bolts, dowel pins, allen keys etc with hot & cold forging process for domestic and overseas customers.

Implemented in-process quality control tests during cold & hot forging which reduced total rejection by more than 15% and enhanced company’s moral and benefits.

Introduced control charts for machining process and reduced machine and workers idle time.

Worked on product design and quality inspection, while working with vendors and suppliers.

Develop better work allocation plans for efficient utilization of machine and labor.

Supervised procurement and quality testing of procured raw material, tools and instruments.

Worked with Manufacturing Resource Planning group for better control of raw material, production quantity, inventory control, material handling and coordinate with sales department.

Supervised manufacturing and business units to specify and integrate process and methods improvements in the new production methods, compressed air systems, centerless grinding, power tool & fixtures, pneumatic controlled machines, fluids flow systems etc.

Worked on Open Hearth Furnace to find better way of its functioning and temperature control strategy to minimize rejection in heating and cooling of nut and bolts.

Implemented effective cost control mechanisms to meet budget limits.

Personal Strength:

Creative and self-motivated to learn new ideas & technologies.

Ability to teach, train and develop result-oriented team.

Adaptable in attitude, flexible depending upon project needs.

Detail-oriented, good organizing skills.

Good communication, presentation, interpersonal and leadership skills.

Education

Master of Engineering, Mechanical Engineering Aug 2003- Aug 2006

Delhi University, India

Bachelor of Engineering, Mechanical Engineering Aug 1991- May 1995

Maharshi Dayanand University, India

Master of Business Administration, Finance & IT Sep 2007- Aug 2010

Wayne State University, Detroit MI USA

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