Engineer Design

Professional Summary

Mechanical Engineer with around 13 years of experience in product design and electrical cable routing in Aerospace and Automobile Industry. Worked in Zodiac Seats US, AGCO, Kenworth Trucks, DAF Trucks (L&T) and Komatsu (L&T).

Expertise in Electrical routing of aircraft seats and Combine Harvester. Sheet metal design of automobile parts, Plastic injection molding & Piping design.

Expertise in modeling casting components like Cylinder Block, Cylinder head, Valve Cover, Flywheel housing, Crankshaft, Transmission case, Steering case, and Exhaust Manifolds and exceptional drawing reading skills.

Experience in designing and modeling of Hood, Fender, Cabin-Roof, AC-ducts, Heat shields, Hood Fender Reinforcement, Engine mounts and brackets for trucks.

Worked on Caterpillar, Cummins engine Installation program for Kenworth Trucks in Air Intake, Fuel Filter and Engine Mounts.

Demonstrated experience in collaborating with cross functional groups including manufacturing, assembly, quality, sales, marketing and field service.

Worked extensively in creating 3D models, assemblies, Manufacturing drawings and Installation drawings.

Knowledge of ASME Y14.5 GD&T and Tolerance Analysis (1D & 3D)

Conduct DFM, DFMEA and Root Cause Analysis

Qualification - Bachelors degree in Mechanical Engineering (4 year), India.

- Pursuing for PMP certification.

Engineering Software (CAD) Skills

- 20,000 hours of Pro E experience (Part Modeling, Surfacing, Cabling, Harness, Diagram, Piping, Sheet metal, Mechanism, assembly, drawing and detailing). Pro/Intralink, Windchill.

- 3000 hours Catia V5 experience (Assembly, Harness Routing, and Drafting).

- Exposure to Unigraphics, Inventor, AutoCAD, E3, ANSYS (Structural).

Employment Experience

Zodiac Seats US, Gainesville, TX (Contract Design Engineer) (Oct’2011 – Till Date)

Designed sheet metal mounting bracket/thermoform shroud for power module and Electronic box. Plastic Injection moulded housing/shrouds are also designed for mounting various components such as monitor, RJU and Ac-outlet on aircraft seats.

Responsible for routing harnesses and creating electrical (IFE) installation for commercial aircraft seats on Airbus, Boeing flights in accordance with FAA and EASA.

Creating Equipment Location Layout, Block Diagram, Grounding Bonding Calculation, IFE functionality test procedure and performing Thermal/Waterproofness test on seat.

Participates in design reviews throughout each phase (PDR, CDR, Tooltry, FAI, MOC7) of the new product introduction process. Communicates technical information effectively and professionally to the customers and suppliers.

Follow-up/Support the program on all stages of Protobuild and assembly build, until the seats are shipped out of the facility.

AGCO Corporation, Hesston, KS (Contract Design Engineer) (Oct’2010 – Sep’2011)

Involved in Design and Development of sheet metal boxes like Battery box, REDC box, LHH box and various brackets required for the Electrical system. Cost effective weldment boxes are created by considering ease of manufacturing and assembly. Tolerance stack up (1D & 3D) was performed to loosen the tolerance.

Development of Electrical system for Class 6 and 8 Combines. Various Electrical harnesses like Main, Left hand, Engine, Rear, Grain bin, Folding grain bin, Under deck, Feeder, Battery group, Cabin and Console are optimized for best routing path and clamping location.

Executed the project in a collaborative environment where design undergoes continuous improvement in every prototype release. Interdepartmental design reviews, vendor development, cost reduction, experimenting new design possibilities will be a part of daily activities.

Responsible for resolving issues arising in Proto and Pilot build concerned to Electrical harness routing.

Based on the E3 script file, harness routing is created using Pro/cabling bundling method with all the necessary clips, clamps and hardware’s. Harness manufacturing and Installation drawing was created with all the necessary information.

Larsen & Toubro Limited, India (Senior Design Engineer) (Apr’2007 – Sep’2010)

Responsible for performing design changes in SRX MK1.2, 15.9l Engine for DAF Trucks. Positioning of ALFDEX Unit, EGR, Lubrication and fuel system, CCV unit with suitable mounting arrangements and pipe routing

Positioning of a single stage turbocharger in place of a dual turbocharger with necessary mounting arrangements. Heat shield is designed for turbocharger and EGR pipe. Exhaust valve brake is positioned on the engine with suitable mounting bracket.

Modifications in water pump, fuel lines, EGR pipe, CAC cold casting, and auxillary water pipe are made as per client requirement.

TRX engine project involves modeling of all parts in 6 Cylinder 16 Valve engine and creation of assembly, Manufacturing and EPL drawings as per DAF standards.

Cylinder block and Cylinder head casting models are modeled using Top-down design methodology; Master skeleton is created to control the outer cast part and all cores. Other casting parts like Valve Cover, Flywheel housing, and Exhaust manifolds are modeled as per requirement. Parametric model of Oil Pan, Oil filter is done from IGES.

Kenworth Trucks, Kirkland, WA (Contract Design Engineer) (May’2006 – Mar’2007)

Responsible for validating the re-usability of existing components in the Truck while installing the latest engines from Cummins and Caterpillar on existing trucks. Required new components where designed for this 2007 Emission Program by means of standardized clearance checks and final interference check for these components with the surrounding components under static and dynamic conditions.

Designed brackets for the Engine mounted Powercore air cleaner. Y-Pipe, Cowl pipe and turbo pipe for the Cowl mounted air-cleaner are designed suitably.

Designed Liquid and Discharge Hardlines for the Heat Ventilation and Air-conditioning lines. Suction, discharge, and liquid line hoses were routed with best clamping location. CAC pipes were designed for different combination of cooling module.

Coordinated 8 member team in India for product design and modification.

Hose routings for fuel-filter lines, power-steering lines, fill-vent lines, transmission oil cooler lines, etc. and hard line routing for HVAC, CRM and air compressor.

Larsen & Toubro Limited, India (Design Engineer) (Dec’2004 – Apr’2006)

Responsible for designing sheet metal brackets for mounting Air cleaner and Engine with ISO welding symbols for Peterbilt Motors.

Sheet metal Hood reinforcements and Heat shields for Turbochargers are designed and manufacturing drawings are created as per ASME standards.

Truck Hood, Fender, Cabin-Roof, AC-ducts, Reinforcement and various other Cab components are modeled in Pro/Surfacing according to client ideas and input.

Prepared Mid surface models for FEA analysis, involvement in result interpretation and optimizing models based on FEA results.

For Komatsu, Japan 2-piece boom was modelled in Pro/E using Top down design methodology which simulates the actual working cycle of the boom during operation to perform Kinematic analysis and Linkage simulation.

Manufacturing drawing for mono boom, chassis are created with GD&T as per Y14.5.

Hoses are routing for optimal path using Pro/Piping.

Sharp Industries, India (CAD Engineer) (Jan’2004 – Nov’2004)

Product development of various components & Reverse Engineering of centrifugal pump impellors. Issuing Machining and Pattern drawing with ISO tolerance.

Designing Prototype & Interaction with Tool Room for new developments and involved in the day to day activities of design department. Developing Manuals and assembly Instructions for Production assembly line.

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