RAKESH UDUPA

Rochester, MI-*****

Mob +1-248-***-****

Email: ad0szh@r.postjobfree.com ; ad0szh@r.postjobfree.com

Linkedin:- www.linkedin.com/in/rakesh-udupa

SUMMARY

** ***** ** **** ********** in Product Design, Development & Manufacturing of Automotive components in Automotive Exterior, Chassis, BIW and HVAC.

Work Experience: 1:-

Magna International (Via Satven, in Michigan-USA) Nov2018-June2020 & Feb 2021-Present.

Role:- Sr. Design Engineer.

Responsibilities:

Exterior Parts Designing, Concept development & Coordination. Class A evaluation & Feedback.

Worked on End to end Ford projects for -U55X, U71X, P800 from start to release and Change Notice.

Concise Design Release summery include:

Using Class A, Creating Master sections to evaluate Part packaging and Fastening feasibility.

Creating rough 3D Concepts/Proposals to understand the shape, packaging, DFM, DFA, Process, sequence.

Class A Feasibility and Feedback on Draft (different for Grained, Painted parts etc), Possible Parting line, Crown, Homologation, etc.

Background/Surrounding parts retriveability & traceability, packaging

Designing Parts on Design Standards, Packaging, DFM, Tooling, DFA, DFS, Assembly sequence, Load study, Process, Driver Tool clearance and provisions etc.

Understanding CAE Analysis report and brainstorming to get corrective actions/Counter measures.

Attending Customer, Supplier, Tool shop meetings to discuss on issue escalation & resolutions and team alignments.

Packaging or Mounting supplier parts into Fascia assembly like Parking sensors, Radars, Reflex, BUNA, Antenna, Harness, WAL etc.

Design Validation, Quality checks, BOM creation, supporting work on DVP&R. Data Management in Teamcenter, Centro.

Extensive design activities on: Front Fascia, Rear Upper & Lower Fascia, Energy absorbers, Sill/Isolator bracket for Front & Rear, Rear Step Pad, Tow cover, Hitch Cover, Chrome parts.

Other activities include- Coordinating with team for Design direction & Delivery planning, Concept Development, Problem solving, Tooling feasibility study, Bench marking, Pendulum setup & Impact study, DFM, DFA, DFS, Loading study, Product clearances, Resolving assembly defects & packaging, Team Center data management, Parts/ Products Drawing release, Executing Change Notice.

Work Experience: 2:-

Webasto Roof system (Via Satven in Michigan, USA ) Jun 2017- July 2018.

Role:- Sr. Design Engineer.

Responsibilities:

Subject Matter expert of Rollo assembly.

Parts include Fabric, Plastic Bearings (Structural-PBT), Splitter, Tension & Extension bars, Shaft, Electro static discharge element, etc.

End to end of Rollo assembly design. Creating Master Section to Design Release.

Creating & maintaining BOM.

Designing technicalities for Rollo assembly include Hard stop, Couplers overhang, Fabric tension and sag, Fabric Rolled and developed length calculations with min clearances at both the conditions, Attack angle.

Redesigning Plastic Housing, Designing Metal Cable routing design considering DFM, Corner piece.

PDM Management. Maintaining color complexity.

Making 3D Proto and testing.

Work Experience: 3:-

DENSO Automotive Deutschland (Via Satven, in Eching, Germany) Feb-2016- Feb-2017.

Role:- Sr. Design Engineer.

Responsibilities:

Automotive HVAC components like Motor Holder, Blower Cases, Distribution Cases.

Improving Motor Holder shape for Noise reduction & better flow.

Changes to Cooling channel in Blower case & Motor Holder for better distributed cooling to Motor & electronic pins.

VAVE by reducing screwing, improving Ribbing to reduce material thickness, Motor Wire length reduction. Project cost reduction based on Tooling, Parts, Material or Process.

R&D for improving Motor Cooling, Easing the PTC installation techniques. Reducing Sliders to reduce costs.

Worked on prototype models to optimize Air flow for Motors, Reduce noise.

Cable clippings for ease of Assembly & serviceability during blind operation.

Work Experience: 4:-

Honda R&D America inc. (Via L&T, in Ohio, USA). Feb2011-April2014

Role:- Industrial Engineer

Responsibilities:

Extensive work on designing BIW-Floor (Under Body) for SUV. Worked on Underbody- Floor and Pillars. Worked on designing Floor Structure by formability and different Fastening techniques like flow drill screws, Welding (Spot or MIG), Mechanical Fasteners.

Sedan Sports Car Trunk design. Volume created with Golf bag & luggage bag- loading, unloading & packaging. With this data, opening of the Trunk was created. Rest designed with packaging the surrounding parts. Carpet is designed to the Layout.

Designing Mesh lower & Front Bumper for a Pickup truck, Designing Dash Insulator & Carpet (Trims), creating RPT parts (Rapid prototyping), Braces design for improving Vehicle performance based on CAE results. Experienced in Fog Lamp mountings on to the Lower Bumper.

Worked on Enlarging Rear Bed & Trunk redesign for a pickup truck (Tire trey, Pan, Cross member, Bed Pivot). Packaging, minimal Design changes to existing background parts, weldings, tool changes.

AGS Air Duct Designing, Packaging for smooth air flow with least decibel levels.

Layout creation to study the kinematics of parts in Trunk lid.

Model Based dim (MBD), FTA are extra skills used in Catia for scope of work.

Work Experience: 5:-

ORGANIZATION: Arvin Meritor Pvt. Ltd., Bangalore. Sep 2009-Aug 2010

Role:- Design Engineer III

Responsibilities:

Packaging, Designing, concept development of different Sunroof modules like, Frame, Carriage, Glass Panel, Rollo blind assemblies.

Creating 3D & 2D with mentoring a 2 member team for Sun Roof design for a Parent company in Germany.

Providing project updates to the Management in a weekly team meetings.

Interacting with the coordinator at Germany for work related activities.

Creating Layout Drawings for the Sun Roof. Implementing GD &T. Creating 3D models R&D changes.

Use of Kinamatics module in Catia for Analyzing mechanism of the parts in Sun Roof.

Work Experience 6:-

ORGANIZATION: HCL Technologies Ltd., Bangalore. Dec 2006 to July 2009

Role:- Design Engineer (Member Technical staff)

Responsibilities:

Worked as a team mentor & member (with 6 member team) for a Aero structural project with “Alenia Aeronautica”.

Managing project deadlines, Issue tracking-Used PM tool to track the Deliveries & Reworks, Project updates to management, Documents recording (from Customer, Suppliers, Design Team, Management, Concepts/Proposals, CAE, Tooling, PDM etc) and Traceability. Mentoring Teammates on structures of an Airplane, DFM of sheetmetal design.

Coordinating with Inter team for executing different projects activities like Packaging, Technical requirements, Deliveries, issues sharing.

Structural parts predominantly Sheetmetal or Aluminium castings. Knowledge of Manufacturing is prime need. Trained on Manufacturing requirement, GD&T.

Experienced in Cockpit, Center Fuselage, Rear Fuselage, Empennage, MLG, Wing, Doors. NMG-Surface is used as Input. Redesigning parts to optimize the assembly for ease of DFM & DFA. VA/VE for certain assemblies as per Customer.

Interacting with clients/Customers (Italians) for any Queries and issue resolutions.

Tools used-Team Center (Enovia) for PLM/PDM, Vis Mockup & DMU for viewing large assemblies.

Work Experience 7:-

ORGANIZATION: RADEL ATG Pvt. Ltd., Bangalore Mar 2006 to Dec 2006

Role:- Design Engineer

Responsibilities:

Worked as a Design Engineer at R&D Department for Aero structural component manufacturing.

Reporting to the Director & planning, RFP for development of Mechanical dept.

Estimation & Costing for the upcoming projects in time required, manpower required manufacturability, suppliers.

Design Validation, modeling & redesigning of secondary brackets for electronic components of an LCA fighter Airplane. Follow up activity with Vendor in manufacturing of the parts up to assembly.

NPD:- New product development of an Plastic cabinet from generating Class A to detailed design of internal parts. The cabinet is modeled by iterations to get the aesthetically pleasing casing for a musical instrument, Squeezing it to the smallest limits by packaging. Handmade Prototype of thermocoal made for visual Aesthetic looks & feasibility study.

Detail Design of each parts for Tongue & Groove locking of 2 halfs, Speaker mounting, Battery compartment, Push button & PCB mounting, Servicability was carried out with DFMEA and VAVE.

Creative ideas for Battery door locking, Speaker & PCB mountings.

Developed a Tool concept for Pin bending fixture & a concept for a 3 direction traverse of Veena (Musical instrument) Bridge with simple & cost optimized manner. Reporting to the Director for all activities.

Interacting with Suppliers for Secondary parts Quality & deliveries.

Underwent Training on Manual Designing parameters of components for structures of an Airplane.

WORK EXPERIENCE 8:-

ORGANIZATION: SAN MOTORS Ltd. Bangalore, OEM. Aug 2005 to Mar 2006

Role:- Product Engineer

Responsibilities:

Development project of redesigning Chassis (Rolling Chassis) to mount Upgraded Engine (from RENAULT to TOYOTA) & allied components.

Worked with 2D drawings for Engine packaging, mountings until the engine arrived.

Designed & Packaged Engine mountings considering DFS, DFA, DFM, existing tool requirements etc.

Design modified Fuel tank to mount bigger Fuel Pump.

Design modified & mounted accessory parts like Air Filter, Drive shaft, Wiring Harness, Exhaust Pipe, steering rack mounting, Fuel pump, Bonnet, Gear shift lever mountings, Radiator mountings.

Reverse Engineering to get 3D points using Co-ordinate Measuring Machine (CMM).

Handled projects of developing FRP components & Resin Mould Transfer process.

Resolved a reoccurring problem of the carry over dynamic part- Upright (Fork/Knuckle) by deep dive on installed actual car parts.

WORK EXPERIENCE: 7:-

ORGANIZATION: JAP ENGINEERING, Bangalore, Ancillary to BEL. July 2004 to Aug2005

Role:- Quality Control Engineer

Responsibilities:

Redesigning and maintaining design standards in process and Manufacturing. Parts include Offroad truck parts, Cabinates/Casings.

Maintaining Quality (Non destructive) of the process for a component based on the value addition, assembly & customer requirement. In-process inspection to final inspection.

Initial tool (press) run- defects capturing and possible solutions.

Translating complicated blue print drawings into machined output.

Estimating and scheduling of the components based on the output delivery time.

Vendor visit & inspection for the optimum quality of the product.

Preparing RPTIT (Routing Process Tooling Inspection & Testing), PPM rejections using graphs, Cause and effect diagram for major PPM, Pareto Analysis. Implementing Innovative ideas for deliverables.

Additional Tools & Software experience:

CAD: Catia V5- Part, GSD, Drafting, Aerospace Sheetmetal design, Assembly, Volume creation, DMU, Kinematics, Function & Tolerance, MBD, Fit Volume creation, Kinematics (Basics). Basics of UG NX.

Familiarity: Press Tools & Precision Mfg., Jigs & Fixtures, Injection Moulding, Machining processes

Hands on: MS Office, Visual Mock up, Team center (PLM& PDM), Matrix one, NAVI.

EDUCATIONAL QUALIFICATIONS

B.E. in Mechanical Engineering from Bahubali College of Engineering affiliated to Visvesvaraya Technological University, Karnataka, India in July’2003 with 66% University Percentage.

VISA: H1B Visa, Currently placed in Michigan.

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