Mechanical Design Engineer

HARI KAFLE

Mechanical Engineer

906-***-**** ******@***.*** www.linkedin.com/in/hari-kafle Houghton, MI (Willing to relocate) SUMMARY

Graduate mechanical engineer with 6 years of experience in automotive OEM demonstrating leadership and communication skills within a team. Proficient in the field of Mechanical design & development from art to part. Seeking a full-time position starting from Aug 2020. PROFESSIONAL EXPERIENCE

Engineering Deputy Manager

Maruti Suzuki India Limited Jun 2016 – Aug 2018 Gurgaon, India Maruti Suzuki India Limited (MSIL), a subsidiary of Suzuki Motor Corporation, Japan, is India's largest passenger car maker. Worked as Deputy manager in Engineering -> Transmission division ->Automated Manual Transmission (AMT) of passenger car. Selected projects from this role:

Project: Y1K AMT New Model Development

• Prepared and presented concept design for review for new model Y1K AMT related to AMT transmission group.

• Performed DMU study for the clearance/Interference between components in static as well as dynamic condition and released technical report. Performed BOM registration, sourcing initiation (RRFQ), drawing release.

• Preparation of jigs for clutch stroke loss estimation test along with testing team. Calculated the clutch stroke by applying GD&T on component dimensions as well as using the stroke lost estimated from the test.

• Attended design proto build of the vehicle. Solved parts issue raised by assembly plant ensuring design for assembly & service. Oil seepage from AMT Tank

• Proposed new oil tank with provision antisplash wall & Oil Plug for the problem of oil leakage. Tool development go-ahead given to supplier after conducting drawing specification meeting with supply chain, Quality engineer and supplier.

• After testing OK of proto part developed, coordinated with supplier for new part development with countermeasures.

• New process audited and reviewed PFMEA and PPAP document at supplier end.

• Countermeasure checked in part level, assembly level and vehicle level testing as part of the DVP.

• Executed the Oil plugs replacement in YCA TM before Production Proto (PP) vehicle build with coordination between TM plant & Vehicle Plant.

Project: Gear engagement problem

• Initial investigation showed that this AMT model specific problem was found to be caused by improper assembly of electro- valves in PCB of the TCU. Identified the temporary containment action & implemented immediately in the assembly line.

• Visited the tier II supplier of Spacer (injection molding product) at Shanghai China and after thorough investigation & observations, root cause established as a manufacturing process change that was directly related to the issue.

• Technical report released with findings and also observations were presented to the senior management.

• Suggested robust countermeasure plan with and coordinated with TIER I and TIER II supplier for smooth implementations. Engineering Assistant Manager

Mahindra & Mahindra Limited Aug 2012 – May 2016 Mumbai, India Mahindra & Mahindra Limited is an Indian multinational car manufacturing corporation. Joined as graduate engineer trainee (GET) and worked in design related tasks of tractor powertrain. Selected Projects: Customer problem if air in fuel problem:

• Root cause of the failure identified using DOE. Introduced an electric pump between fuel tank & inline injector.

• Developed of new pipes & mounting brackets which includes 3D modelling, 2D drafting, DVP&R (FEA, lab and field testing).

• Collaborating with other departments, assembly trial conducted, and engineering drawing released in the ERP system. Dry Type rear axle design:

• Customer reported Problem of leakage from rear axle oil seal was investigated by warranty data analysis, failed part analysis, 7 QC tools for root cause identification.

• New dry type design proposal of rear axle with 2 oil seal & one mud block seal arrangement. Ensured design for design for manufacturing, assembly and service through proper dimensioning, tolerances and DMU front loadings.

• Conducted Design review, DFMEA & DVP&R along with all stakeholders.

• Modified design of the affected components in UG-NX & Drawing released in Teamcenter PLM. Implemented the project by collaborating with CFT (Supply chain, Manufacturing, Process engineering, Quality etc.) after successful assembly trials. COMPUTER and TECHNICAL SKILLS

CAD (UG-NX, SolidWorks, AutoCAD), MATLAB, Simulink, GD&T, DFMEA, Teamcenter(PLM), Lean Tools, ANSYS, DVP-R, Injection molding, Six Sigma Practices, Sheetmetal Design, ASME Y14.5-2009, Plastic Design, Finite Element Analysis (FEA), Microsoft Office (Word/Excel/PowerPoint/Outlook/project), Problem Solving, Analytical Skill, Root cause analysis EDUCATION

MS Mechanical Engineering GPA

Michigan Technological University 08/2018 – 05/2020 3.5 / 4.0 B. Tech Mechanical Engineering GPA

National Institute of Technology Durgapur 08/2008 - 05/2012 7.8 / 10.0 ACADEMIC PROJECTS

Project: Kinematic & Dynamic Modeling of Biped Robot Spring 2011 to Spring 2012

• Modelled biped robot using Catia V5, Kinematically & dynamically simulated using ADAMS view & Matlab and matched results from both the simulations.

• Presented the findings in national conference ‘Recent Trends in Trends in Engineering & Science (NCRTES-2012)’ Organized by Prestige Institute of Engineering and Science, Indore, India. Project: Dynamic simulation of jib crane with load Spring 2019

• Simulated jib crane with used in lifting load with adjustable horizontal position and vertical rope length.

• Derived differential equation for payload using Lagrange’s equation and stabilized model using Baumgarte stabilization method.

• Implemented both original and stabilized models using a signal-based approach in Simulink. In addition, implemented a third model using the component-based approach of SimScape Multibody to verify the signal-based solution. Project: Half-Car model analysis using analytical Vibro-acoustics Fall 2019

• Created the stiffness and mass matrix for the half-car model using the element mapping method and modeled in MATLAB to find the natural frequencies and the mode shapes. Verified the matrix values using Newton’s method.

• Computed the FRF (Phase/Mag) with output at different Degrees of Freedom.

• Calculated the magnitude and phase of the response at the steering column and seat due to given random road profile.

• Studied the stiffness effect on the mode shapes of the vehicle. PHEV Propulsion System Analysis Spring 2019

• Build AMESim model for different Electrification Architectures for propulsion system of an automobile (EV, Series PHEV, Parallel PHEV & Powersplit PHEV) and accessed the performance and energy flow.

• Calibrated the model to get best MPGe on EPA test cycles for both city and highway driving.

• Developed a Pugh matrix with the most relevant performance characteristics or engineering attributes and proposed the best solution.

• Calculated gear ratios from power flow for a 6-speed Speed FWD Planetary automatic transmission. Determined clutch truth table and found the torque ratio value of each applied clutch for a given gear state. Calculated required friction surface area for clutch disk to withstand the torque requirement.

EXTRA CURRICULARS

• Certified for Mahindra Yellow Belt for completing project to eliminate transmission breather oil leakage problem.

• First Place, ‘Transporter’ Robotic competition: Event organized in annual tech fest ‘AAROHAN’ of NIT-Durgapur, India. Robot designed had to make bridge in the trench to pass by, and be able to travel in road containing water, sand, stones etc. to collect and deliver maximum numbers of goods.

• TA in MTU Physics department: Displayed leadership skills in guiding students through laboratory sessions and laboratory report writing, designed experiments for understanding of physics concepts such as electricity, magnetism, optics, and mechanics.

• Certified value engineer from SAVE international.

• Vice president in NSO MTU (2019-20): Demonstrated initiative & leadership skills from planning to execution of many programs

• Active member of ASME

• Volunteer in A World in Motion (AWIM) from SAE India.

• Michigan Tech McNair Dinning Hall Student Supervisor (2018-2019)

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