ABID SALMAN SHAIK Phone: 313-***-**** Email: add0dh@r.postjobfree.com

SUMMARY:

• An ingenious and determined individual with 2 years of experience in Product Design & Development and a master’s degree in Automotive Engineering.

• Experienced in Benchmarking, E-BoMs, Change Requests, Design Reviews and extensively used DFMEA, CAD and FEA tools.

• Strong knowledge and understanding in Product Design, Vehicle Packaging, Systems Integration, Automotive Manufacturing Processes – Cold & Hot Stamping, Die Casting, Joining - Welding etc.

• Strong project experience in Model-based & engine performance Simulation, linear & non-linear, static & dynamic FEA.

• Student Formula member (FSAE & SAEINDIA), led the design of the F3 Race Car’s Chassis, Fuel Tank, Driver’s Seat, Steering Knuckle, Suspension Arms, Cockpit Integration & Ergonomics. Hands-on experience with Arc, MIG welding and fabrication.

• Working cross-functionally to implement cost reduction ideas, design optimization and prototype development.

• Good knowledge in quality tools like DMAIC, Ishikawa, PPAP, APQP and DFSS.

• Highly motivated with an automotive mindset looking for a prosperous career path in Product Development and Engineering. RELEVANT EXPERIENCE:

The Woodbridge Group – Product Development Co-op 05/2019 – 04/2020

• Lead an R&D material testing project:

- Coordinated with the laboratories and manufacturing plants for testing procedures, standards, and logistics.

- Test data was recorded and analyzed using Regression analysis in Minitab.

• Conducted Trim DFMEA in compliance with FMVSS 202a/ECE 17 for automotive seating applications.

• Developed a new Head Restraint mechanism design; Benchmarked existing designs in the market, conceptualized design ideas in CATIA V5, evaluated engineering calculations and coordinated in prototype builds.

• Reviewed and initiated testing on components/assemblies as per DVP&R.

• Created E-BoMs through 3D CAD and was involved in all the DFM activities for programs: Toyota (500B, 550B & 922B), Ford

(U540, P702 & P703), GM (31XX), BMW (G09G18), TESLA (MODEL Y), FCA (JL & JT).

• Released ECRs for trim design changes, generated DFM reports and assisted in RFQs.

• Conducted full teardowns of Seats, Head Restraints & Armrests and documented benchmarking database to develop future designs.

• Collaborated and interacted with cross-functional teams to make significant improvements in design engineering & testing.

• Assisted in conducting VA/VE activities to come up with cost-effective solutions. JSW Steel Ltd. – Manufacturing Engineering Intern 07/2017 – 08/2017

• Manufactured a 140T Steel Transfer Ladle Shell used in transferring molten steel to casting facilities / auto-pour unit.

• Developed associated E-BoM based on the drawings received from the design department. Fabricated the plates using CNC Oxy- Acetylene & Plasma Cutting Machine and rolled plates into a shell.

• Machined the fabricated parts based on the route cards. Inspected dimensional accuracy according to QA and assembled the ladle using overhead crane, includes joining the components with bolts and SAW (Submerged Arc Welding). SAEINDIA – Design Engineer Lead & Driver 06/2016 – 05/2017

• Designed the Space Frame Chassis, Fuel Tank, Steering Knuckles, Suspension Arms, Air-Intake System, Engine Mounts, Steering Column Mounts, Knuckles, Exterior Body Panels, Driver’s Cockpit and Ergonomics.

• Sketched, modeled, and built a prototype, considering the suspension points, BOF point, H-point, steering-rack column position, pedal clearance and 95th percentile male specifications in compliance with SAEINDIA SUPRA design guidelines.

• Conducted structural FEA of all the components in ANSYS & Hypermesh OptiStruct simulating deflections and stresses.

• Achieved good strength to weight ratio by implementing AISI 4130 Steel tubes in chassis design, utilized principles like; DFMEA and DVP&R, conducted cost & weight analysis for the design responsible components.

• Recruited and led the design team, organized bi-weekly meetings, made project plans and assigned goals correspondingly.

• Ensured proper packaging and integration of the front and rear compartments. Coordinated with machine shops, supervised logistics, marketing, and sponsorships in this entire journey. TOOLS & DISCIPLINES:

CAD: CATIA V5 & Siemens NX CAE/FEA: Hypermesh, Hyperview, LS-Prepost, LS-Dyna, ANSYS Fluent & Static Structural Other: Teamcenter, Minitab, MATLAB/Simulink, Python, C++, Microsoft Office Tools & GD&T (ASME Y14.5) ACADEMIC PROJECTS:

Design and Analysis of Intake Resonator System for a Naturally Aspirated Restricted Engine. 09/2017 – 03/2017

• Designed and developed an Air Intake System for TATA’s 600cc parallel twin engine used for SAE formula racing applications. Performed steady-state flow analysis using ANSYS Fluent 16.0 to ensure minimal to no obstruction inside the manifold.

• The plenum volume, runner lengths and diameter were varied and experimented in accordance to the Helmholtz resonator theory to gain the minimum pressure drop between inlet and outlets of the system.

• CFD was done in ANSYS Fluent and pre-processing of the system was done using WAVE Mesher for performance analysis.

• Achieved 25.2% and 35% increase in the brake torque and power respectively when compared with the stock specifications. Driver Ergonomics Evaluation on 2019 Lexus ES350 F-Sport 09/2019 – 12/2019

• Evaluated driver’s package as per SAE J1100 to check accommodation of the 5th percentile female and 95th percentile male as per U.S anthropometric data.

• Conducted Human Factors Evaluation of controls and displays located on Steering Column, Instrument & Door Panel and suggested for ergonomic improvements.

• Evaluated driver’s Field of View (FOV) and Vehicle Lighting System under various driving conditions to assess blind spots.

• Evaluated Entry/Egress, Engine and Cargo compartments for ease of usage, service, and maintenance.

• Developed a new Heads-Up Display (HUD) layout based on surveys for the Autonomous Vehicles (SAE Level 3 & 4). Light Weighting & Process Optimization of Vehicle Suspension System 09/2019 – 12/2019

• A research study on alternative material for control arm manufacturing justifies that TBF Steel Alloy (GEN3 Steel) is better than conventional HSLA 420 when compared in strength to weight ratio, elongation, weldability and production cost. Benchmarking and Preliminary Design Specifications of a 2024 MY Small Sized Sedan. 09/2018 – 10/2018

• Benchmarked the competitor vehicles (2018MY Honda Civic EX-L & Nissan Sentra SL) with the 2018 Toyota Corolla.

• Determined customer characteristics through customer surveys to foresee the expected features desired in the future model.

• Developed Pugh Diagram to determine how the target vehicle (2024MY Toyota Corolla) and the benchmarked vehicles compare with its reference vehicle.

• Developed a QFD to convert customer needs into functional specifications for the Front Seating System of the target vehicle QFD, Requirements Cascade and Interface Analysis for Front Seating System. 10/2018 – 11/2018

• Decomposed the seating system into sub-systems, sub-sub-systems etc. till component level.

• Developed the Quality Function Deployment to convert customer needs into functional specifications, Interface Matrix and Interface Diagram for the system and related all the systems, subsystems and components through Physical, Spatial, Functional, Material Transfer, Information Transfer and Electrical Means.

• Understood the tradeoffs - spatial vs space allocated, ease of assembly vs size etc., to be considered while designing the system. EDUCATION:

• Master of Science in Automotive Systems Engineering GPA 3.62 University of Michigan-Dearborn, Dearborn, MI, USA 04/2020

• Bachelor’s in Mechanical Engineering GPA 3.70

Osmania University, Hyderabad, India 05/2018

Design & Core: Design of Automotive Chassis & Body Systems, FEM in Automotive Structure Design, Analysis & Design for Vehicle Crashworthiness, Design of Machine Elements, Machine & Production Drawing and CAD. Automobile - An Integrated System, Total Quality Management, Vehicle Ergonomics, Automotive Manufacturing Processes, Thermodynamics, Heat Transfer, Computational Fluid Dynamics, Mechanics of Materials, Dynamics of Machines, Mechanical Vibrations and Metrology and Instrumentation. Electronics & Modeling: Vehicle Electronics, Modeling of Automotive Systems, Battery Systems Modeling & Control, Applied Electronics and Electrical Circuits & Machines.

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