Engineer Sheet Metal

Ramswaroop Kapistalam Madusudan

Contact: / E-Mail: **********@*****.***, ***********@**********.***, ***.****@*****.***

Ph: +91-994*******

Skype : mr_swaroop

Profile Summary

** ***** ** ***** *xperience in Aerospace mainly in fields of Aero Structures, Aero harness and Flight Test.

Overall 2 years of International work experience in various kinds of roles such as Team member, Onsite project coordinator at AIRBUS and BOEING, Germany and USA.

Having continental exposure and cultural adaptation in Europe (Germany) & USA.

Insightful experience in Project Management activities estimation, resource administration, etc.

Expertise in Structural Design, Harness, Design and Flight Test Design for Aerospace projects

Experience in Engineering Change Requests (ECR) for rail Projects.

Experience in Safety and Analysis Report (SAR) preparation using D0-160F standards.

Experience in Automation using VBScript for CATIA V5 (CATScript).

Knowledge of Advance Excel and VBA Macros.

(Refer to Annexure for Major Projects & Knowledge Purview)

Core Competencies

Project Management

Underwent PMO & PMP internal workshops, institutionalizing the professional project management practices and streamlining the critical planning processes throughout the project life cycle.

Estimation, Planning, Allocating tasks, Time sheet approval, generating billing reports and Invoicing.

Aerospace harness Design

Study of Inputs.

2D to 3D conversion of Harness drawings.

Study of Harness Schematic drawings.

Creation of new harness routings.

Aerospace Structural Design

Design of Frames in Crown, LH and RH panels based on stress reports.

Creating model based definition (MBD) for the above components.

Design of Stringers in Crown, LH and RH panels based on stress reports.

Creating model based definition (MBD) for the above components.

Design of secondary structures such as splices, shear tie back angles based on stress reports.

Creating model based definition (MBD) for the above components.

Design of sheet metal components such as Shear Ties and Stringer Clips based on stress reports.

Carrying out design changes in the above mentioned components.

Optimizing Frames for weight based on stress data.

Flight Test and Instrumentation Engineering

Freezing of Concept which involves finding out the where the Flight Test equipment have to be installed.

Freezing of Design which involves design of secondary structures like sheet metal brackets in mounting Flight

Test equipment. In some cases, also primary structures were re designed to suit Flight Test requirements.

Detail Drawing creation for the installations, assemblies and parts.

Design using hand calculations

Design of components of 3 – geared relay mechanism such as shafts, gears, Mousche to shaft interface, locking mechanism, roller plate etc.

Designing of components related to the four bar mechanisms.

Design of aero foil section.

Engineering Change requests

Studying of Inputs.

Ensuring that all the datasets in PLM are in the latest revision and maturity state.

Creating new revisions of all the concerned datasets (Installations, assemblies, Detail parts and Drawings).

After the above steps, maturity of the datasets will be changed.

Incorporating the design changes suggested by customer and sending the same for reviews.

Safety and Analysis Report (SAR) preparation using D0-160F standards.

Studying of Inputs PDF reports and determining all the tests to be performed for the Qualifying component based on the testing components.

Classification of Environmental and Non Environmental tests for the Qualifying component.

Safety and Analysis Report(SAR) creation for Safety of Flight(SOF) and Test Certification(TC) requirements

Review and delivery of SAR checklist to customer.

PLM Support.

Studying of Inputs.

Performing CATIA V5 R20 validation scenarios.

Solving CATIA V5 and ENOVIA tickets.

Report preparation for customer.

CATIA V5 Automation.

Creation of Macros for changing text height type in drawings.

Creation of Macros for re ordering tree structures in CATParts.

Creation of Macros for Instantiating and re ordering Standard Parts in an assembly.

Creation of Macros for Renaming Skeleton points and vectors.

Creation of Macros for extracting Reference Geometries for Drawings.

Creation of Macros for generating STP files from CATProducts.

Organizational Experience

From July’19 till July’20 with UMLAUT (Formerly known as P3 Consulting Engineering Private Limited)

Designation:

July’19- July’20 Lead Engineer

Highlights:

BOEING Green Aircraft Design and Model Based Definition

Type 1

oStudy of inputs (CATIA V5 Parts)

oCreating Model Based Definition for all the parts

oDelivery to customer

Type 2

oStudy of inputs (CATIA V5 Parts and BOEING supplied seed models)

oAnalyzing similarity and differences between the allocated parts.

oRaising query in case of any discrepancies.

oCarrying out Design changes in the model in lines with the seed model.

oCreating Model Based Definition for all the parts in similar lines with GD&T in seed model.

oDelivery to customer

From Mar’19 to June’19 with TATA HAL Technologies Limited

Designation:

Mar’19-June’19 Consultant

Key Result Areas:

Successfully executed 3D modelling of BOEING 737 Max Vertical Stabilizer.

Highlights:

BOEING 737 Max Vertical Stabilizer

oStudy of inputs(CATIA V4 Master model)

oParametric modelling of the CATIA V4 Master model to CATIA V5 using reference master geometries

oConducting Peer Level Quality Checks.

oDelivery to customer

From Nov’18 to Dec’18 with FERCHAU ENGINEERING

Designation:

Nov’18-Dec’18 Design Consultant

Key Result Areas:

Successfully created 2 macros as per customer requirement

Highlights:

BMW Continental

oUpdating drawings for BMW lithium batteries.

oAnalyzing concepts for new assemblies and creating reports.

oCreating a macro for STP creation from CATIA V5 session.

oCreating a macro for creation of STP files from one folder to another.

From May’12 to May’17 with CYIENT, rebranding name of Infotech Enterprises Ltd., Hyderabad

Designation:

May’12-May’17 Project Leader

Key Result Areas:

Assisted in RFP creation for Boeing Flight test and Instrumentation Engineering based on past experience. The project was eventually awarded to CYIENT.

Led a team for 2D to 3D creation for OH-58D project from day one without any training.

Assisted Triumph Vought teams in execution of Pilot Flight test projects.

Highlights:

2D to 3D conversion of OH58D defense Helicopter

oLeading a team of 12 members and assigning datasets to them with deadlines

oPerforming peer level quality checks.

oDefect entry for internal turn backs.

oApproving, time sheets, leaves etc.

oGenerating weekly billing report.

oRRCA for escapes from customer.

oConducting trainings for team members.

oAttending weekly status call with customer.

Boeing Test and Evaluation

oFreezing of Concept which involves finding out the where the Flight Test equipment have to be installed.

oFreezing of Design which involves design of secondary structures like sheet metal brackets in mounting Flight

oTest equipment. In some cases, also primary structures were re designed to suit Flight Test requirements.

oDetail Drawing creation/Model Based Definition for the installations, assemblies and parts.

oCreation of Macros for changing text height in drawings.

oCreation of Macros for extracting Reference Geometries for Drawings.

DCP Structures(CATIA V4 to V5 conversion)

oExecuting CATIA V4 to V5 conversion of some datasets.

oStudy of Inputs and Planning

oAssigning conversion tasks to associates.

oTracking the day to day progress of each associate using internally developed excel sheets.

oQuality Control (QC) of the tasks completed by associates.

oDelivery of datasets to Boeing.

oConducting daily meetings with team members.

oPreparing daily Minutes of Meeting (MOM).

oInvoicing.

oCreation of Macros for re ordering tree structures in CATParts.

Conducted training of the internally developed new E3 tool which is a substitute for existing SAP which was used for time sheet entry, invoicing etc.

Bombardier Transport Engineering Change Requests(ECR)

oStudying the inputs and analyzing the design changes suggested by customers.

oEnsuring that all the datasets in PLM are in the latest revision and maturity state. If no then send a query to customer and get the same.

oCreating new revisions of all the concerned datasets (Installations, assemblies, Detail parts and Drawings).

oModifying all the concerned datasets (Installations, assemblies, Detail parts and Drawings) as per the inputs.

oAfter modifications are done the maturity of all the datasets are changes as suggested by customer.

oQuality control of all the datasets.

oDelivery of datasets to Bombardier.

MITAC Safety and Analysis Report (SAR) preparation using D0-160F standards.

oStudying of Inputs PDF reports and determining all the tests to be performed for the Qualifying component based on the testing components.

oClassification of Environmental and Non Environmental tests for the Qualifying component.

oSafety and Analysis Report(SAR) creation for Safety of Flight(SOF) and Test Certification(TC) requirements

oReview and delivery of SAR checklist to customer.

MDS Aero 2D to 3D conversion

oStudying of Inputs PDFs.

oCreation of 3D models, assemblies and drawings using AUTODESK Inventor.

oSelf check and peer review of all the drawings

oDelivery to customer and incorporation of feedback from customer.

From Sep’11 to May’12 with IBM India

Designation:

Sep’11-May’12 PLM Consultant

Highlights:

Bombardier Aerospace PLM

oRunning CATIA V5 scenarios in the specified environment for CATIA V5 R20 Validation.

oReporting functional defects if any to Dassault Systems.

oResolving CATIA V4 tickets from users.

oResolving CATIA V5 tickets from users.

oResolving ENOVIA LCA tickets from users.

From May’10 to Sep’11 with Mahindra Satyam

Designation:

May’10-Sep’11 Technical Leader

Highlights:

Bombardier Flight Test and Instrumentation Engineering

oFreezing of Concept which involves finding out the where the Flight Test equipment have to be installed.

oFreezing of Design which involves design of secondary structures like sheet metal brackets in mounting Flight

oTest equipment. In some cases, also primary structures were re designed to suit Flight Test requirements.

oDetail Drawing creation/Model Based Definition for the installations, assemblies and parts.

oCreation of Macros for changing text height and type in drawings.

oCreation of Macros for extracting Reference Geometries for Drawings.

Bombardier C-Series Mid Fuselage

oAnalyzing stress reports for fastener type and pitch

oLeading a tem for Creation of rivet points in CATIA Models i.e. skeleton model creation.

oDesign of Frames in Crown, LH and RH panels based on stress reports.

oCreating model based definition (MBD) for the above components.

oDesign of Stringers in Crown, LH and RH panels based on stress reports.

oCreating model based definition (MBD) for the above components.

oDesign of secondary structures such as splices, shear tie back angles based on stress reports.

oCreating model based definition (MBD) for the above components.

oDesign of sheet metal components such as Shear Ties and Stringer Clips based on stress reports.

oCarrying out design changes in the above mentioned components.

oOptimizing Frames for weight based on stress data.

oCreation of Macros for Instantiating and re ordering Standard Parts in an assembly.

oCreation of Macros for crating Skeleton Vectors based on the available skeleton points.

oCreation of Macros for Renaming Skeleton points and vectors.

From Nov’06 to May’10 with Tata Consultancy Services Limited

Designation:

Nov’06-May’10 Assistant Systems Engineer

Key Result Areas:

Pride at Boeing award 8 times

Name appearing in TCS success stories.

Awarded TCS gems.

Highlights:

Boeing 787 Customer Intro.

oIRM creation for Cargo Handling Systems using Model Based Definition.

oIRM creation for Water & Waste Systems using Model Based Definition

oParametric modeling of Seat Track Cover in Seating Systems including.

oIQA and checklist creation for the above.

Boeing Flight Test and Instrumentation Engineering

oFreezing of Concept which involves finding out the where the Flight Test equipment have to be installed.

oFreezing of Design which involves design of secondary structures like sheet metal brackets in mounting Flight

oTest equipment. In some cases, also primary structures were re designed to suit Flight Test requirements.

oDetail Drawing creation/Model Based Definition for the installations, assemblies and parts.

747-8 Design Cell

oStudy of Inputs (KBE Generated Drawings).

oCleanup of the KBE drawings which include arranging texts properly, providing GD&T etc.

oSubmitting the drawings for checking to the Boeing Focal.

oInvolvement of offshore team for drawing cleanup tasks and performing Onsite coordination tasks

From Sep’05 to Nov’06 with Satyam Computer Services Limited

Designation:

Sep05’10-Nov’06 Engineer

Highlights:

A340 Long range SFM Design

oStudy of inputs which includes the studying of ZAMIZ(Drawings) and ZUBERLISTE(Parts List)

oCreating 3D harness models from 2D drawings using CATIA V4

oChecking for clash with the surrounding components suing CATIA V5.

oModifying the bundles based on the clash check.

A380 Harness Design

oStudy of Inputs which include analyzing the schematic diagram(VKE)

oPlanning harness route.

oRouting the harnesses using CATIA V4.

oChecking for clash with other ATA chapters using DMU tool Dvise.

oChecking for TDD compliance with other ATA chapters using DMU tool Dvise.

From Sep’04 to Sep’05 with Sreetech Designers

Designation:

Sep’04-Sep’05 Contract Engineer

Highlights:

oSolid and surface modeling of various components of the engine lathe in a project entitled “Monitoring the spindle bearings and gear box in a lathe using vibration and shock pulse”.

oSolid modeling of the rubber boot in a project entitled “Analysis of a rubber boot using Finite Element Method”.

oSolid modeling of the doe holder of a solid fuel briquette press in a project entitled “Analysis of a die holder of a solid fuel briquette press”.

oSolid modeling of a connecting rod of an auto engine.

From Sep’03 to Sep’04 with National Aerospace Laboratories

Designation:

Sep’03-Sep’04 Project Graduate Trainee

Highlights:

Deployment of Mousche of a Light Combat Aircraft using shape memory alloys (SMA)

oDesign of components of 3 – geared relay mechanism such as shafts, gears, Mousche to shaft interface, locking mechanism, roller plate etc.

oSolid modeling of above-mentioned components and also additional components such as bearing housings, housing caps etc.

oDesigning of components related to the four bar mechanism such as SMA holding blocks, plate holders, Lever arms, connecting links, slider brackets etc.

oSolid modeling of the four bar mechanism related components.

oSolid modeling of the aero foil section of CFRP Mousch.

oDesign of jig for holding the lugs.

Radio Controlled Blimp.

oDesign of Rear ring and front ring.

oSolid modeling of Rear and front rings.

oSolid modeling of arch.

oSolid modeling of Skid.

oSolid modeling of Rear landing gear.

From Jul’03 to Jul’04 with RVE Technologies

Designation:

Jul’’02-Jul’03 Trainee Engineer

Highlights:

Underwent training in Unigraphics v18 in parametric and un-parametric modeling of solids, surfaces (free form features) and sheet metal. Later on involved in teaching of Unigraphics V18.

IT Skills

Well versed with:

oMS Office: (Word, Excel and PowerPoint), Lotus Notes and Outlook Express

oCAD Software: CATIA V5, CATIA V4, Unigraphics V18, Autodesk inventor

oPDM/PLM Databases: ENOVIA VPM, ENOVIA LCA, PDM.

oAutomation Tools: CATScript, VBScript, Excel VBA

oProgramming Languages: C, C++

Academic Details

BE (Mechanical) from Sir M Visvesvaraya Institute of Technology, Visvesvaraya Technological University, Bangalore in 2002.

PUC from Sir M Visvesvaraya Institute of Technology in 1998

ICSE From St John’s High School in 1996

Trainings

ENOVIA VPM by AIRBUS in Hamburg Germany.

E3D by AIRBUS in Hamburg Germany.

35 PDU PMP Training by CYIENT in Hyderabad.

ProE creo cabling training by EDS technologies.

C & C++ training by Genius Information Technology Academy (In association with Microsoft).

Certified Trading Professional India - Online Course by Online Trading Academy.

Core Strategy- Online Trading Academy.

Professional Options Trader- Online Trading Academy.

Professional Futures Trader- Online Trading Academy.

Advance Excel and VBA Macros – Genius Information Technology Academy.

Personal Details

Date of Birth: 12-September-1979

Passport: J7973129 valid till 2021

Address: 1095, 7th main, 9th cross, B.S.K 1st stage, Srinivasa Nagar, Bangalore-560050

Languages Known: Kannada, English, Tamil, Hindi, and Telugu

ANNEXURE

Major Projects

Deployment of Mousche of a Light Combat Aircraft using shape memory alloys (SMA)

A340 Long range SFM Design

A380 Harness Design

Flight Test and Instrumentation Engineering

Bombardier C-Series Mid Fuselage Primary and Structural design.

Deployment of Mousche of a Light Combat Aircraft using shape memory alloys (SMA)

Knowledge Purview

Gained extensive exposure for:

oInvestigation and concept design activities using tools like Catia V5 and VPM (Enovia) for Flight Test projects.

oDesign of Components of Mousche Assembly(Including Airfoil)

o2D to 3D conversion of A340 harnesses.

o2D to 3D conversion of BELL OH-58D helicopter components and assemblies.

oCATIA V4 to CATIA V5 conversion of Boeing Aircraft Components.

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