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Manufacturing Engineering

Detroit, Michigan, United States
January 09, 2017

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SANDEEP KUMAR INGERSAL **** Lake Lila Ln C3, Ann Arbor, MI 48105 Cell: 734-***-****


Seeking a full-time opportunity in Design/Manufacturing Engineering position (Available Feb 6th 2017)


University of Michigan, Ann Arbor CGPA: 3.7/4 Sep 2015 - Dec 2016

Master of Engineering in Global Automotive and Manufacturing Engineering

Relevant Courses: Design for Six Sigma (DFSS), Manufacturing System Design, Systems Engineering

Anna University, MIT Campus, Chennai, India CGPA: 3.5/4 Aug 2009 - May 2013

Bachelor of Engineering in Automobile Engineering

Work Experience

3 months in Tesla Motors Inc. Fremont, CA

Intern – Manufacturing Engineering, Battery Pack Oct 2016 - Dec 2016

●Process Planning & Layout design using AutoCAD for Model 3 Battery Pack Pilot-Production Line in Gigafactory

●Design of assembly fixtures in CATIA for manual assembly of parts

●Planning and procurement of Equipment/Tools necessary for Pilot-Production Line

2 Years in Hyundai Motor India Ltd (India’s 2nd largest automobile manufacturer) Chennai, India

Manufacturing Engineering – Vehicle Body (BIW) July 2013 - July 2015

New Product Launches: SUV - Creta, Hatchback - i20, Sedan – Verna

Job Responsibilities held:

●Planned new facility layout and new process for new vehicle launch projects

●Performed Supplier Quality Development and PPAP process for new vehicle launch projects

●Specification development, vendor selection, purchase and installation of equipment for new vehicle launch projects

●Executed production try-outs with prototype builds and validated equipment, part and process

●Verified R&D BIW part drawings of new vehicles for Design for Manufacturability using CATIA V5

●Analyzed CMM and Gap & Flush data and performed root-cause analysis to identify process variation

●Practiced Simultaneous Engineering (PFMEA, DFM) and proposed design changes to R&D during design fix stage

●Optimized Robots’ cycle time and increased throughput from 58uph to 60uph in Body Side Structure Line

4 Months in Wabco India Pvt Ltd, Chennai, India

Intern – R & D, Reverse Engineering Jan 2013 to April 2013

●Performed competitor study and benchmarked a non-ABS Hydraulic Brake Cylinder of a competitor’s product

●Complete 3D CAD Assembly Model of the benchmarked product was built using PRO-E and performed part study, material study, performance analysis and created Liaison Matrix with Mates table in the benchmarking process

Academic Projects

Chatter Vibration in Milling Operation- Nagoya University, Japan June 2016 - Aug 2016

●Analysed the effect of direction of cutting in the chatter vibrations occurring in deep groove milling of automotive dies. Brass metal was machined using a variable end mill cutter and vibrations were measured using eddy current sensors to analyze the effect. It’s a project of Toyota Motors and Aisin Corporation in Nagoya University

Production Line Improvement - Nexteer Automotive Assembly plant, Michigan Mar 2016 - Apr 2016

●Performed line study and provided production capacity improvement suggestions for a steering sub-assembly line using quantitative analytical methods discussed in Production Systems Engineering course in Univ. of Michigan

Design for Six Sigma - Case Study Mar 2016 - Apr 2016

Applied IDDOV methodology to identify the best design between two different automated droplet systems using DFSS tools like QFD, Dynamic Taguchi Model, DOE, Design Score card, Operating and Warranty Cost Analysis

Assembly Modelling of Screw Gauge Sept 2016 – Nov 2016

●Reverse Engineered a Screw Gauge to study its design & functions and determined the feasible assembly sequence and fixturing methods to achieve the key characteristics of that product

Li-Ion powered Electric car - Shell Eco Marathon Competition, Malaysia Feb 2012 - July 2012

●Designed the Body and Chassis for a mini electric car using Solidworks and fabricated a weight effective body using GFPR material and structure using aluminum alloy with my Team to participate in the Shell Eco-Marathon Competition that challenges students around the world to design, build and drive the most energy-efficient car


●CATIA V5, Solid Works, AutoCAD, PRO E, Basic PLC, Basic Pneumatics, Minitab, Matlab, MS Office

●Languages: English, Tamil, Japanese (elementary) & German (Level 4)

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