Design Engineer Injection Molding

Over ** years of experience in design, development, and integration of various components to form high performance products. I can integrate my engineering knowledge of multiple disciplines to provide a new dimension of creativity. I have a formidable background in structural analysis, component selection, manufacturing processes, and hydraulic/pneumatic system design. Additionally, I have specific experience developing Cab/Canopy/Automotive/Electronic/Consumer/ Crane/Paving products. I would like to provide my skills to an organization which encourages innovating thinking, and provides career development opportunities.

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PROFESSIONAL SUMMARY

SATI SH KUMAR

SEN IOR PRODUCT DEVELOPMENT ENG I NEER

Ph#: 952-***-**** E-mail: ****************@*****.*** SKILLS

CAE tool integrated with PTC Products: Cero–3, Pro Engineer wildfire-4, Pro Sheet Metal, Pro Weld & Pro Mechanica, Math CAD

AutoCAD, AutoCAD Inventor

Team Center, Intralink., and PDMLink

Finite Element Analysis (FEA)

Designing and developing Fluid/Flow Lines and

Hydraulic/Pneumatic systems, sub system schematic

Welding Techniques

ERP: BAAN, Oracle, and SAP

TOOL DESIGN

Sheet Metal Stamping die (Progressive, Deep Draw, Compound, Staging)

Plastic Injection Molds (Single, Multiple Cavities, and 3- Plate Molds)

Sand and Die Casting

Jig and Fixtures

ENGINEERING METHODLOGIES

Design for Six Sigma (DFSS)

Design for Manufacturability (DFM)

Design for Assembly (DFA)

Design Verification Plan and Report (DVP&R)

Value Added/Engineering (VA/VE)

Production Part Approval Process (PPAP)

Advance Product Quality Planning (APQP)

ENGINEERING STANDARDS

GD&T and ANSI Y14.5 –1994 (R 2003) ASME,

ASTM, SAE, and ISO 9001and QS 9000 working

environments

Project Team Leadership

Spearhead several concurrent product project teams (NPI, sustaining improvement, cost reduction, and tooling).

Smoothen team dynamics by defining performance

expectations, ensuring involvement from all members, and aiding data flow within the team.

Mentored junior design engineers with a focus on developing their product design skills, increasing their ability to follow the company’s engineering standards, and complete task on time.

Guiding Customer Interactions

Navigate customer design meetings to develop product concepts and determine their attributes. Additionally, report progress regularly with customers and accommodate any new constraints.

Deliver customer product within budget and time constraints. Design, Development, and Product Integration

Convert design concepts into a CAD model which can be delivered for approval by the customer.

Develop product structure: BOMs, EBOM, MBOM for

weldments, hydraulic/pneumatic systems, control systems, and make appropriate ECN, EDN changes.

Ability to identify the best and cost efficient materials for all ranges of product lines.

Integrate product through top-bottom arrangements

(group-, sub-, and component assemblies).

Supervise Product Testing and Analysis

Craft product test plans, analyze results, and make recommendations for further optimization of

performance and slash costs.

Testing plans focus on evaluating Structural analysis

(fatigue, crack growth, safe-load), dimensional

analysis (stack up tolerance), and Statistical Analysis

(manufacturing process variations).

Supporting Fabrication and Assembly

Contribute technical expertise and enable cross

communication between marketing/sales,

manufacturing, fabrication, assembly, quality

assurance departments, and designs teams.

Technically Aid Field Service

Facilitate field service representatives by updating the design of Legacy Product line as well as replacement of other obsolete product components.

PROFESSIONAL EXPERIENCE

CRENLO - Senior Product Design Engineer Feb 2015 – Cab/Canopy/Car Body Products

Designed Cab products and accessories (i.e. truncates, brackets, jig, fixtures, inspection gauges) for all series and models of motor grader, skid steer loader, and rail cars.

For select above part and accessory development, crafted a laser cut layout.

Conducted ROPS, FOPS testing of Cab/Canopy/Car body products and advised changes to improve product performance.

Shared expertise on sheet metal structure, stamping die, and welding fixtures with several development teams.

Error proofed many varied products lines and series.

Observed work flow on the shop floor and advised changes for increased worker ergonomics and safety. MANITOWOC CRANES - Senior Product Design Engineer Aug 2010 – Dec 2014 Crane Products

Integrated Tier-Interim, Final Engine, Drive Mechanism, and Hydraulic/Pneumatic systems into massive cranes.

Spearheaded projects on incorporating corrosion-free technology into crane products.

Collaborated on a project aimed to improve Variable Counter Weight position systems.

Adapted Boom Tracking System, Boom Rotating Bed, Crawlers, and Car Body for improved crane flexibility.

Directed improvements on hose, pipe, and wiring harness routings which also slashed product development costs.

Established engineering standard for hose and pipe fittings.

Implemented engine cold weather and after treatment packages- exhaust, muffler, and auto lubrication system

Oversaw engine sound proof testing and advised on material and design adjustments.

Troubleshooted engine after-treatment exhaust field issue and implemented modifications for problem resolution.

Supported new products during early hour use, greatly diminishing risk of break down (from 22% to 8%).

Accommodated existing customer products by developing installation tool kits and providing spare parts. RFA MINNESOTA ENGINEERING – (Caterpillar) Product Design Engineer May 2008 – July 2010 Paving Products (Soil-, Asphalt-, Pneumatic Compactors, and Pavers)

Integrated engine, hydraulic/pneumatic, and control systems in Teir-3 and Term-Interim into paving products.

Observed product performance and made appropriate system configuration changes to better adhere to pressure constraints.

Worked to ensure paving product features (i.e. traction control, vibration of wheeled double drum, emulsion/watering, and scraping system) functioned at optimum levels.

Accrued knowledge of paving product early hour brake down issues, and generated improvements for reducing future probability of breakdown (from 14% to 2%). Improvements directly minimized product production/warranty costs.

Updated homologation of the equipment to meet international market standards. HOFFMAN TOOL & DIE - Senior Design Engineer Nov 2001 - Apr 2008 Stamping/Injection molding (Automotive Body, Electronic Device parts and enclosures, Food, Appliances and Consumer)

Built company capacity to produce products by recommending purchase of manufacturing machines (i.e. press shop machines, auxiliary equipment, and Tooling/Sheet Metal product materials).

Oversaw tool room die build activities and pilot runs for new stampings and moldings. Advised on changes for improvements.

Smoothened the manufacturing process by integrating self-developed custom machines and welding fixtures. DELTA AXXION TECHNOLOGY - Design Engineer July 1998 – Nov 2001 Stamping/Injection Molding (Electronic Device Enclosures: personal computers, servers, consumer electronics)

Catered to secondary operations by incorporating self-customized auto machines into the product line.

Defined lean manufacture techniques and recommended stamping machine tonnage requirements to manufacture parts for the above.

Outlined safe operating procedures for use of the stamping die and machine, brake press, and press shop auxiliary equipment. Ensured compliance and maintenance of equipment.

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