Engineer Design

PALANI APPAN(PAL), *, Tollgate Mews, M*M *X*, Scarborough, Ontario, CANADA.

E-mail:*********@*****.*** (prefer to contact),

Toronto, Canada–Home 416-***-****, Cell 647-***-****, NC, USA–Cell: 434-***-****

CAREER OBJECTIVE

Project Engineer – Automation Equipment, Special Machinery, Machine Design, Material Handling Systems.

Mechanical Engineer – Product Design, Tool Design, Project Planning, Product & Process Improvements.

PERSONAL PROFILE

Wide experience in high speed Automated Manufacturing & Assembly Systems, Rotary Assembly Automation.

Automotive industrial experience in Product Design, Development, Manufacturing, Assembly Automation

Experience in different Bearings types, Mounting Arrangements, Bearing Assembly Procedures.

Ball Slides, Linear Bearings, Gear / Chain / Belt Drive systems, Ball Screws, Pneumatics, Servomotor Drives.

High Speed Pick & Place, Transfer Systems, Automated Packaging, Welding, Roll Forming, Vibratory Feeder.

Mat top/Table top Conveyor, Belt/Roller/Rope Conveyor, Plate/Chain Conveyor, Overhead Conveyor systems.

Experience in design & development of loading & unloading station with Fanuc Robots M-2iA, CR Mate-200id

Combined experience in Design, Development & Manufacturing of various products, from different industries.

Knowledge of Root Cause Analysis Tools, Process flow evaluation, GD&T, VE/VA, DFMEA /PFMEA, SPC.

Committed to continuous improvement, Possess good trouble shooting skills, Safety Standards.

Perform engineering analysis to support the selection of parts and materials that meet requirements.

Multi-disciplinary Process and Assembly operations, Automotive Product Design, Tool Design, Jigs & Fixtures.

Design Machines from verbal / sketches, prepare drawings, & guide production, assembly, commissioning.

Experience in designing Compliant Mechanisms to replace Multi parts by a single part for cost savings.

Cycle time reduction, Process improvements with Design for Assembly, Design for Manufacturing concepts.

Perform FEA with Dynamic Simulation to view critical areas of a part, safety levels to optimize dimensions.

Automation Engineering Services, Project Planning, Technical problem solving, ISO Certification

Proficient in Inventor, Solid Works, AutoCAD, CAD Customization, Vault, Auto LISP Programming, CAD/CAM.

Promote Products & ideas through 3D Animation, Multimedia Product Demo Presentations.

Cited as one of the top Creative Designer & result oriented for increasing productivity.

Ability to coordinate a high level of activity under a variety of conditions and constraints.

Ability to work well under pressure in a constantly changing high volume manufacturing environment.

Interacts with various departments including, management, production, electrical to plan & develop programs.

PROFESSIONAL ACHIEVEMENTS

1) Flextronics International, Morrisville, NC, USA (From July 2015) (Contract)

Design Engineer:

Developed a Material Handling system with Pick and Place arrangements up to 250Lb Rolls

Designed a Rack feeding arrangement from Multiple Level to a constant level Belt Conveyor system.

Developed a unique 3-directional working Ratchet mechanism for a special application.

Redesigned a module for Value engineering and reduced cost up to 25% with added additional features.

2) Belvac Production Machinery Inc., (Dover group), Lynchburg, VA, USA (Oct 2011- May 2015) (Contract)

(Leading Automated High Speed continuous motion Rotary Machine manufacturers over 50 years)

Project Engineer:

Developed a Waxing M/c to process a range of products of different diameter and different length with quick change tooling system, and using more commercial standard parts to minimize production cost.

Developed a parametric design Inserts with Autodesk Inventor, possible to develop various component designs in future, by just changing few parameters, to save design and development time.

Developed 3D-Shaped Star wheel concepts with special cutter design, to hold & transfer contoured cans.

Developed a high speed pick and place on a chain conveyor system with Cam operated 3 point grippers

Developed a “Compliant Mechanism” to replace multiple parts of a gripper by a single part for high cost saving.

3) Project Engineer: Robust Gear Manufacturing Inc. Oakville, Canada (July 2011 - Oct 2011)(Contract)

(Special Gears, Custom Gears, Gear Box Manufacturing for Automation Systems & Special Machineries)

Product Design:

Developed a Low cost Open Type Compact Gear Reducer with optional cover plates for space saving. The T-shape & L- shape construction design reduces cost & custom parts can be mounted directly on the reducer.

Created ISO-9001 Procedures, Manuals and coordinating for ISO Certification. Created quality standards, inspection procedures, forms, flow charts, instruction sheets & Quality Auditing systems.

4) Project Engineer: Proline Automation Systems Ltd, Toronto, Canada (Jun.2001 to May 2011) (Full time)

(Manufacturing Automation Systems, Special Machinery, 3 Axis CNC Machines)

Automated Manufacturing System:

Redesigned a heavy duty Cleaning Machine with a C-form casting base to replace 7 machining parts. Prepared casting drawing, stage machining drawings, machining procedures for initial reference face machining. Prepared rejection rectification procedures, to save the partially machined castings.

Conducted FEA with COSMOS on casting base, analyzed stress level at all the critical points, optimized the dimensions and eliminated rejection problem

Developed a high speed Chanel profile Process Line with 4 stage Form Rolling machine, coil straightener, Multi directional Press tool with CAM systems, sensor to stop & start the Rolling machine for next cycle, saving 4 operators job & increasing production by 3 times

Designed an Auto Feeding, Drilling, and Milling Machine with servo controlled Variable angle cutting system.

Modified & standardized above feeding system, and used in many machines to reduce the design time.

Modified existing CNC Controlled Corner Cleaning Machine with 1) Compact 6 tool Rotary system, 2) Auto profile recognition system, 3) Innovative Design of a Loading table with length & width collapsible system

Automated Assembly System:

Developed a high speed Rotary Table Assembly M/c for Automotive Regulator Contact Screws & Nuts assembly with output of 2 seconds per set to match with continues production line.

Designed a multi stage Automatic Starter Coil Winding Machine on rectangular core with build in coil straightener.

Material Handling Systems:

Modified a Single level roller conveyor to a Double layer conveyor for a Double stack Welding Machine with top layer alternatively lowers & off load to one level Belt conveyor which reduced a man power operation.

Product Design:

Redesigned a U-shape casting for a Double Corner Cleaning Machine to improve the performance & reduce machining cost.

Conducted FEA with COSMOS, analyzed stress level at all the critical points & modified product.

Tools, Moulds & Testing Equipment Design:

Developed many Press Tool Design, Drill jigs, Assembly fixtures, Gauges, Test Rigs etc. for various components of Automotive Products with quick change inserts & quick change modular units.

Developed Pneumatic High-Speed Running Test Equipment to run Commutator at 60,000 rpm to check the molding strength at high centrifugal force.

Project Design:

Based on a Japanese Technique (Simultaneous Engineering), Design for Manufacturing, Design for Assembly concepts, an Alternator Assembly Product was redesigned, resulting part count reduction, variety count reduction, operation reduction, and rejection reduction which reduced production cost up to 40%.

Introduced co-ordinate Dimensioning, Tooling hole for angular faces dimensioning, Design reporting format, Quick change modular sub assemblies, Design Rules concept, Component Standardization.

Developed a Fortran Computer Software Applications for 1) Special Cam Design for 3D-Profile Gear Generation for an Automotive Starter Pinion component Manufacturing, 2) Gear Design for Special Cam Milling taper helical flute drills.

Created Customized Menus, Macro Commands & Libraries in AutoCAD to reduce design & drafting time.

5) Project Engineer : Automation 2000, Toronto, Canada. (Oct. 2000 to Apr. 2001) (Contract job)

(Manufacturing Automation Systems, Special Machinery, Conveyors, Material Handling Equipment)

Automated Manufacturing System:

Designed an Automatic Double Side Saw cutting Machine with 1) Auto magazine feeding of Roll Formed profiles to the cutting station, 2) Pneumatic auto transfer system to a deburring station(cycle time:10 sec.)

Developed an Automatic Deburring M/c with 1) Auto Roller feeding by fast picking Roll Formed profiles from a high speed rolling & cutting M/c, 2) Chain drive Auto transfer system to different deburring stations.

Project Design:

Developed a Fiberglass Taper pole or Straight pipe winding Machine by 1) Dipping the multi strand fiberglass rowing in moving resin tank, 2) Winding a helical pattern over a mandrel, 3) Auto helix angle changing system for zigzag multi layers winding for the required wall thickness & 4) Mandrel puller system.

Improved Productivity by 40% by changing Process oriented Layout to an improved Product oriented Layout, utilized the surplus inventory for 4 months and reduced rejection rate using Just in Time concept.

6) Design Engineer : Nova Machinery & Eng. Inc., Toronto, Canada. (Jun. 2000 to Sep 2000) (Contract job)

(Heavy Machinery Design/ Modification/ Improvements - work as per US, Europe, Japan customer requirements)

Product Design:

Custom designed 4 Stage Heavy Duty Gearbox for steel roll forming industries of Canada & USA customers.

Created Custom Designed Parts: Metal, Plastic & Fiberglass Parts for different industries.

Made 3D-Animation presentations for New Product Promotion, Customer approval at the design stage, before manufacturing tools & moulds. This saved lot modification cost & time.

Material Handling Systems:

Designed a Scissors Coil Car 1) to carry maximum of 15Tons Steel Coil on rails, 2) Turn table to rotate 90 degrees, 3) Lift 24” high with Hydraulic system, to unload by fork lift to different stamping presses.

Developed an Overhead crane for an Electro Plating division with 1) Over head Rails & Rollers drive system, 2) Vertical Chain drive system for lifting components with barrels & fixtures, 3) Electrical interlock system.

7) Project Engineer : B & B Production Services, Markham, Canada, (Nov.1999-Mar.2000) (Contract)

Automated Assembly System:

Developed an Automatic Strip Assembly Machine with 1) A belt conveyor to feed various length panels, 2)Apply glue on the Panel edges with auto glue application unit, 3) Pick & Place the rubber strip, 4) Press to paste the rubber strip on panel edge, 5) Move to the output conveyor.

Material Handling Systems:

Designed a Swing & Fold Material Handling System: 1)Belt conveyor to receive Fiberglass sheet from continuous production line, 2) Feed through swinging guide rollers, 3) Fold & load in containers(saving 2 operators manual job).

INVENTIONS – Unique Self Creative & Innovative Designs

(For any Automation Industry to increase productivity & performance)

New Power Ball Slides with Direct Gear Drive System, Remote High Speed Hydraulic Drive Systems

New Linear Flat Ball Bearings with balls Recirculating on Flat & Custom Designed Profiles

New Linear Gear Designs for high speed reduction ratio (which is like worm gears rotary to rotary movement)

1) To get Fine Linear Movement from a Rotary Movement,

2) To get Fine Rotary Movement from a Linear Movement.

New Double directional, Helical Rack to get both fast and slow speed for a single Helical Pinion Gear.

COMPUTER EXPERIENCE

Systems: Windows 10/7/XP, Macintosh, UNIX, DOS.

Software: Autodesk Inventor 2015, Solid Works 2016, AutoCAD 2015, Primavera Project Planner,

Microsoft Project, MS Word, Excel, Access, Power Point, Autodesk Vault, Solid works Enterprise PDM

Programming: AutoLISP, C, C++, FORTRAN, Web Design, Visual Studio 2013

EDUCATION & CERTIFICATION

Degree: M.Engg. - Master of Engineering (Designs) (University of Toronto has evaluated the degree)

Solid Works 2010 from George Brown College, Toronto, Ontario

AutoCAD (all 3 levels), AutoLISP programming, 3D Studio, C, C++, Visual Basic, Visual Studio, Web Design

FORTRAN Programming (for Engineering Calculations), Multimedia in MAC Platform.

PAPERS & AWARDS

New Spiral Bevel GEAR Generation method - Presented in Machine Tool Design & Research Conference

Won the best paper award and paper was published in the University Journal

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