Senior Mechanical Design and Testing Engineer

CURRICULAM VITAE

K. Senthil Kumar

Contact : +971-****-***-**(UAE)

+91-978*-***-***(INDIA)

Email : ************@*****.***

Objective:

Dedicated Senior Product Design Engineer with 15 years of experience in designing innovative

and market-leading products. Proven track record of successfully bringing concepts to reality

through a combination of technical expertise, creativity, and leadership. Seeking a challenging

role to contribute to the development of cutting-edge products and lead multidisciplinary teams.

Professional Experience :

1. R&D Senior Mechanical Engineer,

Company name: Ferco Shutters and seating systems LLC, Dubai (July 2018-Till)

Led the design and development of fire-rated rolling shutters for various applications, ensuring compliance with

relevant industry standards and regulations.

Experience in the testing procedure EN, UL and IMO etc. For Rolling shutter and fire door with hardware .

Fire resistance testing and certification.

Fire rated doors and hardware testing experience.

Coordinate with laboratory activities to conduct the fire test.

Manage the projects from Design, manufacturing, sampling, installation, testing and certification.

Discuss with EN & UL team about the product testing requirements before the testing.

Follow up with production team and vendor.

Technical Support to project,sales and production.

Specialized in Wind load testing for Roller shutter.

Conducted thorough research and analysis to identify emerging technologies, market trends, and customer needs,

resulting in the successful implementation of innovative product enhancements.

Developed and managed project timelines, budgets, and resource allocation to ensure on-time and within-budget

delivery of R&D initiatives.

Skilled in conducting feasibility studies, prototyping, and testing to validate design concepts and ensure reliability and

functionality.

Utilized computer-aided design (CAD) software to create detailed models, simulations, and prototypes, facilitating

efficient development and iteration processes.

Effective communication and collaboration skills, working closely with cross-functional teams including machinists,

manufacturing engineers, and project managers

Conducted UL10B fire resistance tests on rolling shutters according to established protocols.

Operated and maintained testing equipment to ensure accurate and consistent results.

Analyzed test data and prepared detailed reports summarizing findings and compliance with fire safety standards.

Collaborated with cross-functional teams, including engineers and technicians, to ensure product compliance and

resolve any testing-related issues.

Participated in the continuous improvement of testing processes and procedures.

Assisted in the development and implementation of new testing methodologies.

Provided training and guidance to junior team members on testing procedures and safety protocols.

Collaborated closely with architects, engineers, and clients to understand project requirements and tailor solutions to

specific needs.

Played a key role in obtaining certifications from regulatory bodies, including NFPA and UL, by ensuring products

met rigorous safety and performance standards.

Led and executed comprehensive fire testing procedures for A0 marine shutters, ensuring compliance with

international maritime safety standards.

Produced detailed test reports summarizing methodologies, observations, outcomes, and recommendations.

Led the design and development of UL10B compliant rolling shutters with integrated egress or wicket door systems,

ensuring fire safety and ease of evacuation.

Perform comprehensive final validation to ensure that the product is ready for market launch.

Procurement experience.

Selection of standard items from the global market.

Interaction with vendors to select the standard component.

Collecting the quotations from the different vendors.

Work out of costing, shipping time and delivery time with all vendors.

Comparison of product from different competitors.

Collection of samples from different vendors.

Making trial before deliver the component.

Projects involved in FERCO:

A. Steel Roller shutter with egress door fire testing UL10B Std with design and implementation:

-A rolling shutter with an egress door is a specialized type of door system that combines the functionality of a

rolling shutter (often used for security or privacy) with the requirements of an egress door (used for emergency

exit purposes). UL10B refers to the Underwriters Laboratories (UL) fire test standard that evaluates the fire

resistance of door assemblies, including rolling doors and shutters. To design, test, and implement a rolling

shutter with an egress door according to UL10B fire testing standards, you would need to follow a specific

process. Here's a general overview:

-The assembly's performance during the fire test will determine its fire rating (120 minutes.).

-Obtain the necessary certification from testing laboratories, such as Underwriters Laboratories (UL), to validate

the fire resistance rating of the assembly.

-Install the rolling shutter with egress door assembly according to the manufacturer's guidelines and local building

codes.

-Ensure that proper signage and instructions are provided near the egress door to indicate its emergency exit

function.

Certifications:

UL10B Certification in Fire Door Systems, 2023

B. "A0" marine shutter, which typically refers to a fire-rated shutter that can withstand the spread of fire and

smoke for a specified period of time.

-Understand the specific requirements of the marine application and any relevant regulations or standards (e.g.,

SOLAS, IMO regulations).

-Determine the required fire rating and operational characteristics of the shutter (e.g., size, opening/closing speed,

manual/automatic operation).

-Choose materials that are fire-resistant and suitable for marine environments (e.g., stainless steel, marine-grade

aluminum).

-Consider factors such as corrosion resistance, strength, and weight

-Design the shutter frame and panels for structural integrity and stability.

-Ensure that the design can withstand the forces of wind, waves, and potential impacts without comp promising

fire resistance.

-Design a reliable operating mechanism for the shutter, considering both manual and automatic options.

-Ensure the mechanism can function even in emergency situations.

-Integrate the shutter with onboard fire detection and suppression systems.

-Design interfaces that allow the shutter to close automatically when a fire is detected.

Certifications:

Fire rated Roller shutter with A0 steel bulkhead as per the IMO FTP CODE 2010 PART 3

C. Fire rated Roller shutter as per the standard EN1634-1

-Designing and testing a fire-rated rolling shutter according to the EN 1634-1:

-Understand the requirements of the EN 1634-1 standard for fire resistance testing and certification.

-Determine the fire rating needed integrity 240minutes based on the intended application.

-Choose fire-resistant materials for the shutter's components, including slats, guides, and brackets.

-Consider materials that have been tested and approved for fire resistance.

-If the shutter is motorized, select a motor and control system that can ensure reliable operation during a fire

event.

-Include a mechanism for manual operation in case of power failure.

-Design the shutter's frame and components to withstand heat and structural stresses during a fire.

-Consider the expansion and contraction of materials due to heat.

-Design interfaces that allow the shutter to close automatically when a fire is detected.

-Coordinate with fire detection and suppression systems on board.

Certifications:

Fire rated Rolling shutter as per the EN 1634-1 STD.

D. Wind load testing of Roller shutter products

Wind load testing is conducted according to established standards such as ASTM E330, ASTM E1886, ASCE 7, and

other relevant codes depending on your location and application.

E. Modified the Rock wool cutting machine that increased production efficiency by 70% while reducing labor costs by

20%.

F. Bottom bar assembly line created a specialized assembly line for bottom bar, resulting in a 50% reduction in

assembly time and a significant increase in product consistency.

G. To avoid the people to work difficulties in open place constructed one shed with mono rail crane, that increased

production efficiency by 70% while reducing labor costs by 20%.

H. Seating systems designed, developed and implementation for school children two rows and three rows

2. Mechanical Design Engineer, Company name: Sri kalahsthi pipes ltd, Chennai (Sep

2014-July2018)

Collaborated with cross-functional teams, including materials engineers and production specialists, to ensure

designs aligned with manufacturing capabilities.

Utilized Solid Works to create detailed 3D models, assemblies, and engineering drawings for ductile iron pipe

components.

Conducted FEA simulations to assess pipe strength, stability, and response to various loads and environmental

conditions.

Preparation of machine GA & concept layout to finish the pipe products for internal purpose.

Machines like centrifugal casting machines, conveyors, quenching car, cement lining machine and etc.

Design & Development of machines.

Part drawings preparation & release.

Mechanical design calculations.

Structure analysis using Solid Works.

Reverse Engineering.

3. Mechanical Design Engineer, SPM INDIA LTD, Bangaluru, Karnataka, March 2012-Sep 2014

Led the design and development of custom special-purpose machines for various industries, including

Automotive industries.

Design Leak testing machines, pressing machines, turn tables, conveyors and etc.(Special Purpose Machine

Design Engineer)

Collaborated closely with cross-functional teams, including electrical engineers and automation specialists, to

ensure seamless integration of mechanical and electrical components.

Conveyor Design

Utilized Solid Works to create 3D models, assemblies, and detailed engineering drawings, resulting in accurate

and efficient production.

Conducted feasibility studies and simulations to optimize machine performance, efficiency, and safety.

Proficient in machine design, automation, and problem-solving for forward-thinking organizations.

Managed projects from concept to completion, meeting deadlines and budgets while maintaining a high level of

quality.

Apply GD & T for the manufacturing parts.

Selection of Linear motion systems, Ball screws, Hydraulic & Pneumatic cylinders, Motors and Sensors.

Implemented design improvements and modifications to existing machines.

Supported manufacturing and assembly teams by providing clear documentation and resolving design-related

issues.

Assisted senior engineers in designing and testing prototypes for special-purpose machines.

Participated in cross-functional meetings to review project progress and address design challenges.

Gained hands-on experience in machining, assembly, and testing of mechanical components.

Material handling systems design like Conveyors, Turntables, Automated Guided Vehicles (AGVs), Storage

Systems and Cranes & Hoists:

Preparation design concept layout.

Design & Development of machines &fixtures. The overall machine consists of Structure Assembly,Servo

Motor Assembly and Fixture Assembly & Hydraulic Pressing Assembly.

Selection of pneumatic cylinders,sensors, LM systems and other long lead items.

Preparation of part/manufacturing drawings & selection of pneumatic cylinders, sensors, LM systems and

other long lead items.

Preparation of component layout.

Preparation of DAP(DESIGN APPROVAL PLAN)

Preparation of BOM’s.

4.Mechanical Design Engineer, Pee Vee Precision Works Pvt Ltd, Chennai, Tamil Nadu-India.,

Aug 2007 - March 2012

Led a team of engineers in the design, development, and optimization of multi-spindle drilling and tapping

heads for various industrial applications.

Utilized CAD 2D technical drawings of drilling and tapping head components, ensuring precision and accuracy.

Collaborated with manufacturing engineers to develop efficient machining processes and tooling setups, resulting

in improved productivity and reduced cycle times.

Extensive experience in the design, development, and optimization of multi-spindle drilling and tapping heads for

industrial applications.

In-depth knowledge of precision engineering principles, GD&T tolerances, and meteorology to ensure

high-quality product performance.

Led the design and development of jigs and fixtures to enhance manufacturing processes and ensure product

quality.

Strong understanding of machining processes, tooling, and cutting parameters..

Collaborated closely with manufacturing teams to understand process requirements and design fixtures that

improve accuracy, repeatability, and efficiency.

Assisted senior engineers in the design and prototyping of jigs and fixtures for new product development.

Conducted research to identify innovative materials and techniques for improving fixture performance and

durability.

Participated in cross-functional meetings to discuss design requirements and address design challenges.

Gained hands-on experience in the manufacturing and assembly of mechanical components.

Mentored junior engineers on GD&T principles and best practices, contributing to their professional growth

Multi spindle Drilling and Tapping head with gear arrangements

design to special purpose drilling and tapping machines.

Drill and Tap tool capacity calculation for different material.

Power & speed calculations for drilling and tapping operations.

Selection of Gear drive, belt drive and bearing .

Basic design calculations .

Jig and Fixture design for Automobile component.

Problem solving in manufacturing and assembly areas & erection and commissioning.

Strong design calculations, material selections and Material heat treatment process.

NEW PRODUCT DESIGN AND DEVELOPMENT KNOWLEDGE

Idea Generation

Market Research

Concept Development

Feasibility Analysis

Detailed Design

Prototype Development

Engineering Analysis

Materials Selection

Manufacturing Process Selection

Testing and Validation

Cost Analysis

Refinement and Optimization

Documentation

Intellectual Property Protection

Production and Scaling

Launch and Marketing

Feedback and Continuous Improvement

Regulatory Compliance

Sustainability Considerations

Team Collaboration

Skills:

1. CAD software (Auto Cad, Solid Works)

2. Fire safety standards (NFPA, UL and EN)

3. Product testing and certification

4. Costing

5. MS Office

6. Fire Safety ·

7. Fire Protection Engineering

8. Passive Fire Protection ·

9. Fire Protection ·

10. Timekeeping ·

11. Project Cost ·

12. Product Inspection ·

13. Engineering Documentation ·

14. Experience in Fire resistance and testing industry ·

15. Fire rated Door and door hardware testing ·

16. UL and EN Certification and testing ·

17. Sheet Metal ·

18. Creative Problem Solving ·

19. Office 365 ·

20. Metal Fabrication

21. Microsoft Products ·

22. Design Engineering ·

23. Product Design ·

24. Manufacturing Engineering ·

25. Product Management

Educational Qualifications

Education Institution Board Year

10th Govt.High School, Yembal State Board Tamilnadu 1998

12th Govt.Boys Higher Secondary School State Board Tamilnadu 2000

, Aranthangi

B.E Mechanical Raja College of Anna University, Chennai 2007

Engineering Engineering technology

Personal Details

Fathers Name - Mr. Kalimuthu

Date of birth - 16 March 1983

Marital Status - Married

Nationality - Indian

Languages known - English & Tamil

Hobbies - Listening Music, Surfing Net, Watching Social news

Permanent Address - House No. 2/53 Maravanayal, Irumbanadu(PO),

Avudayarkoil(TK), Pudukkottai(Dist.) Tamil Nadu,

Area Pin code – 622204.

Declaration

I hereby declare that the above information is true and correct to the best of my knowledge and belief.

Senthil Kumar

Place

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