Mechanical Designer

S. Rao Potru

**** ***** ***** ******, *** 226

Arlington, VA 22209-2895

Mobile: 248-***-****

ad2g1r@r.postjobfree.com

OBJECTIVE

Mechanical Designer

SUMMARY

Thirty-seven years of experience in Engineering, Manufacturing and Management in addition to a Ph.D. in Mechanical Engineering, Systems Development and Project Management

Chaired the General Motors corporate committee to evaluate CAD and CAM systems and establish the CAD/CAM and PLM) strategy for the design and manufacture of automobiles.

Developed and executed a vision for the implementation of solid modeling technology in the design and construction of stamping dies and body shop tools. These technologies are estimated to save $20 million in tool and die construction costs annually. This project was nominated for the President’s Council Award in 1998and 1997 and it received the Manufacturing Center’s Excellence Award in 1996 and 1995.

Holistic Process Improvement and Implementation

Development and Motivation of people and teams

Excellent Project Management and Communication Skills

INDUSTRIAL EXPERIENCE

2015 – 2016 – Commonwealth Center for Advanced Manufacturing, Disputanta, VA

Title: Machining Researcher

Accomplishments: Investigated the current machining practices of aerospace materials like super alloys and hardened steels and proposed improvements.

2013 - 2015 - New Hampshire Ball Bearings, Inc., Peterborough, NH

Title: Manufacturing Engineering Manager

Accomplishments: Managed the manufacturing engineering department and the tool room in supporting the fabrication, assembly and testing of ball and roller bearings. Established a rigorous lean philosophy and project management methodology to improve the processes to support manufacturing of ball and roller bearings.

2009 - 2013 - The Boeing Company, North Charleston, SC

Title: Manufacturing Engineering Manager

Accomplishments: Managed the manufacturing engineers in developing installation plans and supporting the assembly of Boeing 787 Dreamliner aft body and mid body. Supported the configuration of the airplane.

2006 - 2009 - Honeywell International, Rocky Mount, NC

Title: Manufacturing Engineering Manager

Accomplishments: Managed the manufacturing engineering department in developing routings for the assembly and testing of fuel control products used on aircraft and helicopter engines.

Managed 43 lean manufacturing projects implementation.

Instituted a rigorous project management structure and discipline.

Developed a 5-year rolling capital equipment strategy and managed the capital budget of $ 2 M for the plant.

Managed the SAP support staff for master data, routings and business objects.

1983 – 2006

Development Engineer (Project Leader of Manufacturing Engineering Toolkit Group), Math-Based Manufacturing Engineering, Strategy, Standards and Tools Department (Reported to the Director)

Managed the development of math-based strategy for automotive body assembly tools, checking fixtures, and dimensional engineering.

Supervised 6 GM engineers, 6 EDS programmers, and one contract engineer.

Proposed a new project to integrate the processing, tool mechanical design, tool control design for body manufacturing.

Initiated and chaired the Corporate (CAD/CAM) Manufacturing Modeling focus team.

Chaired the Corporate(CAD/CAM) Math-Based Program Library Focus Team.

Development Engineer (Project Leader of Solid Modeling Group), CAD/CAM Department (Reported to the Manager)

Responsible for the management of a development project to improve the productivity of 100 patternmakers and 50 NC programmers by a significant factor. The group consisted of 10 GM and EDS engineers in developing the system.

Managed a project to engineer stamping dies for structural soundness using appropriate analytical tools like PATRAN and NASTRAN along with Unigraphics solid modeling technology.

Provided technical and management consulting to Packard Electric Division in the implementation of CAD/CAM technology to electrical component engineering and manufacturing activities.

Provided consulting to GM Brazil in CAD/CAM strategy for die design and manufacturing.

Organized and chaired the Corporate Committee for the evaluation and selection of tactical solid modeler and long term strategic solid modeling kernel for the GM C4 environment. The solid modeling products evaluated include Parasolid, ACIS, IDEAS, CADAM-ISD, CATIA, PRO/ENGINEER and ARIES. The team included 8 GM engineers from various segments of the business and 4 EDS professionals.

Senior Project Engineer, Metalworking Technology Department (Reported to Supervisor of Machining Process Technology Group)

Provided technical consulting to engine, transmission and die manufacturing plants in processing and machining strategies and techniques.

Developed Die Machining Advisor for the selection of machining operations, cutting tools and parameters.

Developed Knowledge-Based Process Planning System to generate machining operations, machine tool requirements and tolerance chart for transmission rotational parts.

Developed machinability database for machining engine, transmission and stamping die components.

Developed machining parameters for the machinability of high silicon aluminum cylinder blocks.

1980 - 1983 - The Ingersoll Milling Machine Company, Rockford, Illinois ($200M sales)

Titles: Development Project Manager of Advanced Technology, and Senior Research Engineer of Cutting Tool Development

Accomplishments: Responsible for product and process development in machine tool and cutting tool products. Leveraged the University of Illinois and University of Wisconsin in the development and implementation of mathematical models.

1978 - 1980 - Micromeritics Instrument Corporation, Norcross, Georgia ($20M sales)

Title: Production Engineering Group Leader of Research and Development Department

Accomplishments: Managed the engineering of three new particle technology and liquid chromatography products and introduced them into production. Managed the design, and quality control functions of the high-technology company.

TEACHING EXPERIENCE

As a graduate teaching assistant, I assisted in Manufacturing Processes, Automatic Controls, Materials Science, and Materials Technology.

Taught the following courses as an adjunct faculty:

Macomb Community College

Die Theory

Wayne State University

Manufacturing Processes (Instructor for Junior Level Course)

Machine Design (Instructor for Senior Level Course)

Advanced Mechanics of Materials (Instructor for Graduate Level Course)

Advanced Vibrations (Instructor for Graduate Level Course)

Lawrence Technological University

Engineering Graphics using Solid Edge 3D solid modeling software (Instructor for Sophomore Level Course)

Material Removal Processes (Instructor for Junior Level Course)

Metal Forming and Joining (Instructor for Junior Level Course)

Introductory Robotics (Instructor for Senior Level Course)

Advanced Robotics (Instructor for Senior Level Course)

Computer-Aided Manufacturing (Instructor for Senior Level Course)

Georgia Institute of Technology

Manufacturing Processes (Instructor for Senior Level Course)

Automatic Controls (Graduate Teaching Assistant)

Materials Science (Graduate Teaching Assistant for Sophomore Level Course)

Materials Technology (Graduate Teaching Assistant for Sophomore Level Course)

EDUCATION

Certificate in Management of Technology (1991) - The University of Michigan, Ann Arbor (GM Education Department)

Ph.D. in Mechanical Engineering (1979) - Georgia Institute of Technology, Atlanta

M.S. in Mechanical Engineering (1974) - Indian Institute of Technology, Madras, India

B.E. in Mechanical Engineering (1972) - Regional Engineering College, Warangal (National Institute of Technology, Warangal).

SPECIAL SKILLS

Experience in project management, process re-engineering, parametric engineering, and analysis. Consulting skills in CAD (Computer-Aided Design), CAE (Computer-Aided Engineering), CAM (Computer-Aided Manufacturing), and PLM (Product Lifecycle Management) technologies. Managed engineering software development. Executed new projects to improve the process. Conducted simulation and analysis of product and manufacturing processes and systems. Experience in using Unigraphics, iMAN (Information Manager), PATRAN, NASTRAN, Robcad, IGRIP and Silma. Familiar with the following CAD systems: PROENGINEER, CATIA, Solid Edge and Solid Works. Coached waste elimination workshops (5S, and GoFast!) in engineering process.

INFORMATION TECHNOLOGY (IT) SKILLS

Experience in software project management. Expert in Microsoft Word, Excel, PowerPoint and Project and Lotus Notes e-mail system and the Internet. Programming skills in C, C++, Lisp, Fortran, PL1 and Basic. Artificial Intelligence (AI) shell programming experience in KEE (Knowledge Engineering Environment) and ProKappa. Experience in programming in Unigraphics CAD environment. Managed the development of the following systems: Parametric die design and manufacturing system, Knowledge-based tool design system, Knowledge-based process planning system, and Die machining advisor.

GLOBALIZATION EXPERIENCE

Experience in globalization of product and process technology in Europe (Germany, and Sweden), Asia (India, China and Japan), South America (Brazil) and North America (USA, Canada and Mexico). Experience with global engineering and parts suppliers. Established a satellite project center at General Motors Technical Center in Bangalore, India and managed the operation successfully. Received bachelor and master degrees in engineering in India.

PROFESSIONAL ACTIVITIES

Member of the American Society of Mechanical Engineers (ASME)

Senior Member of the Society of Manufacturing Engineers (SME)

Member of the CASA/SME University Lead Award Committee (1999, 2000, 2001)

SME Certified Manufacturing Engineer since 1977

Chairman, Chairman-Elect, Treasurer and Secretary of SME Detroit Chapter One (2001, 2000 and 1999)

Served as a member of the Industrial Advisory Board at Wayne State University, and Lawrence Technological University

HONORS AND AWARDS

Charleston Engineering Joint Council's 2013 Engineer of the Year

Society of Manufacturing Engineers' 1999 and 2004 President's Award

General Motors NAO Manufacturing Center's 1996 Special Achievement Award

General Motors NAO Manufacturing Center’s 1995 Special Achievement Award

Engineering Society of Detroit’ Affiliate Council Award (2004)

COMMUNITY ACTIIVITIES

Served as the Chief Judge at the spelling competitions at the Regional Level and National Level conducted by the North South Foundation (not for profit organization based in Chicago, Illinois), 2004, 2003,2002, 2001,2000,1999, 1998, and 1997.

Coached a team of six ninth and tenth grade students from Rochester Adams High School to participate and win second place in the Michigan Council of Teachers of Mathematics (MCTM) competition, 1997

Coached MATHCOUNTS team at Van Hoosen Middle School in Rochester Hills, Michigan, 1996 and 1995

INTERNATIONAL GLOBALIZATION EXPERIENCE

Asia

India: 25 years, education High School (First Ranker), BS and MS degrees in Mechanical Engineering

Japan: Consulting with SUZUKI and ISUZU

Korea: Consulting with GMDAT (GM Joint Venture Partner)

North America

Canada: SME University LEAD Award site visit

PUBLICATIONS AND PRESENTATIONS

1.“Product and Process Design and Management” Track Co-Chair at the SME First Annual Manufacturing Technology Summit – 2004, August 10, 2004.

2.“Manufacturing and CAD/CAM” presentation at Unigraphics Fall 2000 User Group Meeting, September 2000.

3.Several internal presentations to General Motors senior management

4.“Fundamentals of Machining Processes,” one-day seminar (with 116-handout) presented at SME’s Technical Conference at the International Machine Tool Show (IMTS Chicago), September 1996.

5.“Die Pattern Construction using Computer Solid Models,” General Motors Record of Invention (with William S. Hopkins and Harold D. Kingsbury) November 8, 1995.

6.“Industry Trends in CAD/CAM/CAE,” industrial perspective presented at the Northwestern University’s Technology Review on Product Design, October 30, 1995.

7.“Solid Modeling in Design and Manufacturing,” presentation to the SME’s (Society of Manufacturing Engineers) North American Manufacturing Research Institution Board of Directors, January 1995.

8.“Parametric Die Design and Manufacturing System, “ presentation to General Motors Science Advisory Committee, July 15, 1992.

9.Solid Modeling in Automotive Design,” presentation at the CAD/CAM Section of the AUTO-TECH 91, Technical Conference of the Automotive Industry Action Group, September 1991.

10.“C4 Solid Modeling Kernel Evaluation Report,” General Motors internal document (174 pages), July 15, 1991 (with Robert Bauer, Frank Demasek, Vasu Devan, Al Fabris, William Hopkins, jim Lyles, Tom Nadeau, Ernest Otani, Dave Rogers, Joe Streng and Balaji Yelamanchili)

11.“C4 Solid Modeling Kernel Evaluation Plan,” General Motors internal document (236 pages), October 24, 1990 (with Vasu Devan, Ernest Otani and Jim Lyles)

12.“Solid Modeling Fundamentals,” one-day technical seminar (with 83-page handout) presented to GM engineers and managers, August 1990 (with Balaji Yelamanchili and Jim Lyles)

13.“Feature-Based Process Planning System for Machined Components Using Expert Systems Technology,” invited technical presentation at the SME Advanced Machining Systems Seminar, November 1988, Seattle, Washington.

14.“Solid Modeling,” moderated a graduate class offered by Ohio State University through the GM Education Program, June 1988.

15.“Feature-Based Process Planning,” technical paper presented at the Manufacturing Technology Session of the General Motors Product Engineering Technology Conference (PETC) 88, June 1988.

16.“Feature Based Process Planning System for Machined Components Using Expert Systems Technology,” paper presented at the ASME 1988 Manufacturing International Conference, April 1988.

17.“Machining and Metal Casting,” co-chaired (with Rani Agarwal) the technical session at the General Motors’ Technology 85 Conference, April 1985.

18.“Effect of Variable Chip Load on Machining Performance in Face Milling,” paper presented at the Eleventh North American Manufacturing Research Conference, May 1983 (with Richard DeVor and Shiv Kapoor).

19.“Analysis of Cutting Forces in Face Milling of High Silicon Casting Aluminum Alloys,” paper presented at the Tenth North American Manufacturing Research Conference, May 1982 (with Richard DeVor and Shiv Kapoor).

20.“A Study to Improve the Life of High Speed Steel Tools with Ion Plated Refractory Compounds,” unpublished doctoral dissertation, Georgia Institute of Technology. Atlanta, Georgia, October 1979.

21.“Application of Nonlinear Goal Programming to Machining Variable Optimization,” paper presented at the Sixth North American Metalworking Research Conference, April 1978 (with C.H. Jacobs).

22.“Numerical Control for Machine Tools,” unpublished Master’s report, Indian Institute of Technology, Madras, India, August 1974.

CITIZENSHIP

United States of America

Courses Taken

Management of Technology Certificate Program at the University of Michigan

1.Strategy, Technology and Management of Innovation (Semester Course)

2.Financial and Management Accounting (Semester Course)

3.Managing Change in a Technology Intense Setting (Two-day seminar)

4.Strategic Marketing (Two-day seminar)

Ph.D. Program at Georgia Institute of Technology

1.Feedback Controls

2.Nonlinear Controls

3.Experimental Statistics

4.Design of Experiments

5.Electron Microscopy

6.X-ray Diffraction

7.Plastic Deformation

8.Metal Forming Theory

9.Metal Casting Theory

10.Forecasting Theory

11.Operations Research

12.Probability

13.Mathematical Modeling of Systems

M. S. Program at Indian Institute of Technology

1.Metal Cutting

2.Unconventional Manufacturing Processes

3.Machine Tool Design

4.Machine Tool Dynamics

5.Controls in Machine Tools

6.Metrology

7.Theory of Mechanisms

Bachelor of Mechanical Engineering at Regional Engineering College, Warangal, India

Math Courses:

1.Mathematics I (Differential Calculus)

2.Mathematics II (Integral Calculus)

3.Mathematics III (Differential Equations)

4.Mathematics IV (Vectors)

5.Mathematics V

6.Mathematics VI

7.Mathematics VII

Pre-University Course (12th Grade)

Mathematics (195 out of 200)

Secondary School Leaving Certificate (SSLC)

Composite Mathematics (90 out of 100)

First Ranker in High School

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