Design Engineer

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SRINIVASA RAO CHANCHALI

Washington, Michigan

+1-248-***-**** • *****************@*****.*** • LinkedIn Sr. Product Engineer

Eminent engineering professional with 15+ years’ experience leading complex and design projects. Demonstrated success of directing designated teams to meet quality standards, strict timelines. Well-versed in nurturing solid relationships and healthy synergies with key stakeholders. Stellar management expertise leveraged to efficiently execute projects and accomplish milestones. Versed in spearheading solid relationships and consistent communication with clients, teams, and executing management.

Core Competencies:

Project Management

Planning Schedules

Catia v5,Creo, NX and Auto Cad

PLM windchill Management

12years of Automotive experience

in electrical Power steering system

Product Design & Development

Aluminum pressure die castings

Plastic molds and stampings

Design of Assembly tooling’s and fixtures

Hot and cold forging die design

GD&T &DFMEA

Professional Experience

SATVEN,ZF-Washington,MI

Sr. Product Engineer, 2014 – Present

Formulated DVP&R/PVP&R in accordance with customer specifications. Headed key aspects of the project, including creation of control/testing plans, reviewing of tested parts, and preparation of test reports. Oversaw project documentation, including DFMEA and BOM while assisting with PPAP. Ensured CV/DV testing and prototype operations continue seamlessly by efficiently managing prototype shop and test labs. Acquired durability testing and NVH requirements through forging strategic synergies with systems engineering team. Run rigorous inspections on power steering to identify defaults and come up with remedial measures/action plans. Officiated multiple projects from design through completion. Key Achievements:

Pilot design and development of Power head (Gear Box) for Electrical Power Steering Column drive projects

Officiate Output shaft, Input shaft, and T bar and ECU and Motor integration

Mounting Bracket design and development for ECU and Harness route, considering strength and vibration.

Gear box housing-pressure die casting and Plastic outer bearing carrier.

Oversee functions of Worm wheel and worm shaft. Quill shaft and sensor assembly.

Take part in key design meetings where core product engineers map out stacks, layouts for Column drive system.

Conceived poka-yoke process to mitigate consistent mistakes.

Tolerance stack-ups, packaging and 2D layouts considering GD&T

Pilot Design and Development of ERCB steering system

Pilot design and development of Front wheel Actuator and Hand wheel actuators for steer by wire steering system Selected Projects:

EPS Column Drive - GM G1XX (Sedan and SUV), CHRYSLER MP551, MP552, MP553&MP556 (C SUV) Steer by wire (Front wheel actuators and Hand wheel actuators) -TESLA eRCB (Electrical recirculating ball)

SRINIVASA RAO CHANCHALI

Page Two

Senior Specialist (Satven INDIA, ZF/TRW), 2008 – 2014 Assumed project lead role and presided over design and development phases of Electrical power steering Belt drive and Seat Belts. Directed offshore team composed of 15 competent design engineers and kept abreast of project daily activities through reports from team members. Demonstrated project management acumen by overseeing projects from conception through completion, including planning, execution, and documentation. Supervised two shifts, devised strategic processes to streamline daily operations and boost productivity. Piloted team responsible for all the residential designs with almost 80 % of internal parts packaging. Executed tolerance stack up projects for TRW EPS Belt Drive and Column Drive Team utilizing VIS- VSA; formulated tolerance stacks up reports to ensure proper GD & T and assembly process. Executed layouts at design validation stage for Yoke/ Pinion plug stack layout, EPP rotation layout, and Ratchet Layout. Performed Engineering changes and data management using PDM Web and PDM link. Administered cradle layout for omega housings in order to assess tolerances required for foot mount holes.

Key Achievement:

Led timely delivery of project by motivating team members and boosting morale.

Contributed immensely on several EPS gear development phases, from Packaging Gear (Customer Input) to Design Validation.

Assumed design and meshing analysis of Rack and pinion, Rack travel study, and 6T Layout for the packaging information.

Designed Rack and pinion gear and performed meshing analysis.

Drove and executed design of steering gear testing fixtures to scrutinize durability and functionality.

Seat Belts system parts design and packaging study of parts such as Retractor-Pretensioner, Buckle-Pretensioner, Anchor-Pretensioner and its assembly components.

Designed Retractor Mounting bracket, Anchors, Height Adjuster for seat belt system.

Devised robust process and check to remedy regular issues.

Conceived poka-yoke process to mitigate consistent mistakes. Selected Projects:

FORD CD3XX, FORD D3, FORD U502,

GM EPSILON, GM CAMARO, GM ALPHA, GM OMEGA

TITAN Industries Ltd, India

Senior Officer, 2005 – 2008

Championed several design projects in accordance with customer specification and contractual obligations. Architected special fixtures for Non-conventional operations such as EDM. Carried out comprehensive design reviews of prototypes, Identified and highlighted faults/complexities, and made unanimous decisions with Process Engineering Department. Extracted master profiles using Pro-E to produce shearing Tools. Augmented tool performance and life span by using DFMEA, PFMEA, and 8D statistical tools. Engaged with colleagues during small group activities to explore process improvement opportunities. Selected Projects:

Steered design of forming and stamping tools for watch case manufacturing.

Led creation of press and forming tools for watch cases and back covers.

Assumed design of jigs, milling, and turning fixtures for watch case and back covers.

Officiated design of Plastic Molds for Taco leaf pointer- Tata Motors Ltd.

Utilized Pro-E to design Electrodes for manufacturing Forming punch, Die, and Knockouts tools. Education and Credentials

Bachelor’s Degree in mechanical engineering, 2013

JNT University Hyderabad, India

Collaborated on Major project for Design of Spiral Bevel Gear box Post Diploma in Tool Design

Central Institute of Tool Design Hyderabad, India, 2005 Diploma in Mechanical Engineering

Poduru, West Godavari Dist Andhrapradesh, India

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