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Design Engineer Mechanical

Canton, MI
September 21, 2020

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MADHU THOTA Canton MI 248-***-****


9+ yrs. professional experience in Product Design & Development with major Tier-1 and OEMs.

* ***** ** ********** ** Product Design Engineer for Mechatronics products at BCS Automotive.

5 years of experience as Design Engineer for Sheetmetal products at Satyam Venture.

Experienced engineer in working design of Injection molded plastic parts for automotive products.

Professional Experience working in design & development of Electromechanical products.

Extensive knowledge working on UG NX/Catia /Solid works (more than 6000 hours)

Hands on Experience with Catia V5, Unigraphics NX, Solid works and Creo 2D and 3D design.

Experience in dimensioning, 2D & 3D Tolerance Stack up Analysis.

Good Knowledge in Injection molding, Die Casting, CNC Machining and Sheet metal fabrication.

Design Experience from concept to production.

Skilled in GD&T standards per ASME Y 14.5 2009.

Parametric 3D Modeling, design and Drafting using Cad Software’s.

Demonstrated strengths: New project conceptualization and execution. Grassroots advocacy. Team management and public speaking.

Analytical & problem-solving skills, result-oriented team player with ability to manage multiple tasks simultaneously.


Design: UG NX • Catia V5 • Solid Works • Creo • Teamcenter

Engineering: DFM • DFA • DFMEA • DVP&R • DFSS • GD&T

Analysis: 2D Stack up • Vis VSA • Abacus

Processes: Injection molding • Casting• Sheet metal • CNC machining

Materials: Aluminum• Steel• Engineering Plastics• Elastomers• PCBs • FFCs


BCS Automotive Farmington Hills, MI, USA

Role: Product Design Engineer (Aug 2016 - till date)

Designed and developed Automotive Interior Products for GM ETRS from concept.

Responsible for development of Steering angle sensor for Daimler MRA2.

Worked on design and development of various Steering Wheel switches

Supported working Turn Indicator, wiper, Steering Wheel switches for various OEMs.

Instrumental in design of new concepts for Various RFQs.

Conduct product design reviews with Customers for successful TKOs

Optimize design for low cost and limit BOM costs.

Perform engineering design reviews with Customers and update design.

Coordinate work with cross functional teams to close open issues.

Working with Suppliers for Plastic parts DFMs for tool kickoffs.

Develop DFMEA and DVP&R and review with the stakeholders.

Perform complex FEA studies, interpret results and modify design.

Collaborate with suppliers and manufacturing plants to review DFA and assembly operations.

Create 2D component drawings and production drawings using UG NX.

Perform 2D and 3D tolerance stack up analysis using GD&T standards.

Maintain the cad structure data and assembly models in Teamcenter PLM.

Release program assemblies and drawings through ECO system.

Satyam Venture Engineering Services. Hyderabad, India

Role: Design Engineer (Aug 2011-Jul 2016)

Lead a team of 3 Engineers in performing complex 3d tolerance stack up analysis

Provide offshore design support for Tier 1 and OEMs in product design using UG NX and Catia V5.

Involved in design of Sheetmetal components for automotive closures.

Create 2D drawings for Sheetmetal and Plastic components using Cad Software’s.

Involved in design of GE Commercial washer/Drier for Sheetmetal design using Creo

Perform 3D Tolerance stack up Analysis for complex programs using Vis VSA software.

Support RFQs and concept design for Onsite locations in Germany and USA.

Involve in design and development of IECP and Steering wheel switches.

Preparation of PCB panels and Keep out drawings.

Create mockups and protypes using 3D Printing.

Benchmarking competitor products and capture best practices.

Participated in certification level trainings in GD&T.

Release of Customer drawings in engineering systems through ECO system.

Experience in validation through DV, PV testing for high volume automotive products.

Supported in working for Ford Inhouse Clock spring design, up lead and downlead connectors.

Through knowledge in working with various engineering plastics and material selection.

Conduct PFMEA reviews with manufacturing teams and customer reviews.

Prepare documentation and procedures for EOLT (End of Line Testing) and Calibration.

Continuously improving product quality based on customer and peer reviews.

Tata Consulting Engineers ltd Pune,India

Role: Mechanical Engineer (Feb 2010 – Jun 2011)

Experience in working with HVAC ducting, AHUs, Chillers and TES for Infrastructure projects onsite.

Engineering changes based on site requirements



Bachelor of Technology May 2009

Major: Mechanical Engineering GPA: 3.6


Played a pivotal role in winning a $150M business from a major OEM (2.5M volume production) for a smart concept presentation.

Received huge appreciation from Vice President of an OEM, Vehicle Model series, in reaching expectations for a vehicle Gear Shifter Haptics performance, in one of the OEM clinics.

Earned a Customer Award (In Satyam Venture) for best trust worthy and reliable work done for Onsite.

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