Mechanical Engineer Sheet Metal

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Appandai Rajan – RESUME

Address: Madipakkam,Chennai Mobile: +91-730*******

LinkedIn: www.linkedin.com/in/appandai-rajan Email: ************@*****.***

Mechanical Engineer Profile

I’m a Mechanical Design Engineer with manufacturing experience in 3D CAD Design, CNC operations and sheet metal fabrication processes. As a Mechanical Product Designer, I have drafted mechanical components using Solidworks for products including sheet metal bellows, foot brake body design, gear shafts and chain sprockets. As an Assistant Manufacturing Engineer at Bellow manufacturing industry, I assisted with sheet metal fabrication process that includes forming, cutting, and bending operations to fabricate customer specified bellow design. As a Junior Mechanical Engineer at Holden Special Vehicles (Melbourne), I designed a new production layout for rebuilding dash using lean methodologies that increased efficiency of the assembly process of RAM 1500, 2500 and Silverado models by 27.5%. Proficient in all aspects of the mechanical product design, including stakeholder liaison and performing validation and testing process for aluminium and mild steel components. I hold a Master of Manufacturing Engineering from RMIT, and Six Sigma and Computer Aided Design certification.

Key Mechanical Engineer skills

3D CAD Design: Designed and drafted 3D and 2D models using Solidworks/CATIA for projects including a foot brake system and sheet metal blocks. Also, designed 10 bellow components per week in Solidworks as a Manufacturing Engineer at Kathiravan Metal Bellows.

Sheetmetal Operations: Assisted in sheet metal fabrication process using CNC machines for up to 3000mm and 6mm thick sheet metal, including bending forming operations.

Lean-Six Sigma: Implemented DIMAC phases of six sigma that increased overall output efficiency by 30% in Dash Rebuilding process at Holden Special Vehicles.

Design Process: Proficient in managing design process that includes identification, planning, execution procedures and supported for production, engineering, quality department team in foot brake system design and bellow manufacturing.

Product Testing and analysis: Experienced in product testing using NDT (LPT/UT/MPT/RT/VT) methods for solid components including mild steel and all types of iron. Also selected penetrant solution according to characteristics of testing material, material type and performed test preparation that includes calibration, distance setup.

Project planning: Experienced using Excel to analyse costs and budgets for site optimisation, production and manufacturing bellow and dash reassembled cars, as well as MS Project and outlook to plan projects such as Dash rebuilding and foot brake manufacturing.

Quality Management system (ISO 9001:2015): Proficient in developing systematic quality audits (internal and external) according to stakeholder analysis, for products such as sheet metal and NDT tested components.

Qualifications and Certifications

• Master of Manufacturing Engineering RMIT University Accredited by Engineers Australia EA ID 8250389 Dec 2019

• Bachelor of Mechanical Engineering St. Joseph’s College of Engineering Accredited by NAAC Jun 2017

• Lean six sigma-Green Belt TUV SUD South Asia organisation Dec 2017

• Professional in Product Design and analysis CADD Centre Jun 2014

• Modern Project Management Quality/ Risk /Procurement/project closeout Alison Mar 2020

• ISO 9001:2015 Quality Management System Udemy Training Mar 2020 Page 2

Professional Experience

Junior Mechanical Engineer JUN 2019 – MAR 2020 (Contract) Holden Special Vehicles – Melbourne

Key Responsibilities:

Identifying and analysing manufacturing bottlenecks such as double handling errors, waste disposal and inventory complications that increase production time and costs.

Conducting work in progress meeting session with other project members to discuss about project timeline, budget allocation, layout designing, lean tools application.

Defining production targets by establishing KPI’s for assembly of each model (RAM 1500 and Silverado) ad develop value stream process map for assembly models with lean applications to propose new solution.

Optimising production time by preparing a new production assembly layout using Factory Layout Design (FLD) which included new waste management unit, separation of two sections for assembly, and floor markings.

Maintaining standard operating procedure reports for the production line, including assembly and disassembly of parts in dash body, and sequence order of component assembly. Assistant Manufacturing Engineer Nov 2018 – Feb 2019 Kathiravan Metal Bellows Pvt Ltd

A leading Engineering firm specialising in manufacturing metal bellows and expansion joints. Key Responsibilities:

Assisting Senior Engineer in developing CAD 3D models using Solidworks software, including sketching, analysis of design, client feedback, and solving queries.

Designing new bellows models according to customer’s specification, and developing new systematic procedures for bellow manufacturing, including forming the sheet metal, pressing, and bending operations, and welding.

Performing sheet metal fabrication for bellow manufacturing according to specified dimensions that includes cutting, bending, and forming operations.

Managing bellow product data’s using data management software such as Solidworks PDM that includes complete product information, product quality analysis, product dimensions and procedures.

Assisting machine operators for tools setup that includes Jigs fixture and sheet metal processing.

Maintaining Purchase order of raw materials including sheet metal and press machines from external stakeholders.

Simulating bellows using FEA designing tools, and validating their product characteristics including bellow size, shape and type of material, and percentage of alloying materials. Non-Destructive Tester JUN 2015– NOV 2016

GT Management and Technical Training Pty Ltd

An ISO 9001: 2015 certified company, providing technical training to oil and gas, process industries, specialising in development and nationalisation program in Gulf countries. Key Responsibilities:

Assessing and applying in non-destructive testing methods, such as Liquid penetrant method (penetrant selection according to nature of the material), Magnetic Particle testing (Magnetic particle direction alignment to find the accumulation), Radio graph testing (Setup Radioactive material and scan distance to find defects), Visual Testing.

Maintaining daily reports of test specimens and correcting defects such as burs, extrusions, shape dislocations, and holes.

Setting up devices including pressure gauge in radioactive testing and sound frequency recorder in ultrasonic testing and calibrating penetrant testing devices.

Identifying defects such as burs, extrusion, cracks, and other defect causing elements which may damage the material such as Aluminium and mild steel, using penetrant globe or magnetic particles. Page 3

Mechanical Project Experience

Project Name: Redesign of foot brake system - value engineering JAN 2017- MAR 2017 Ashok Leyland Pvt Ltd

Project Overview: To identify errors and inefficiencies in a foot braking system to reduce the complexity and cost of the foot brake used in tipper vehicles, and re-structure their product design. Key Responsibilities:

• Optimising the production process by identifying unnecessary parts that can be removed without an impact on design and efficiency and identifying parts such as screws and bolts that will be eliminated by the re-design.

• Assisting CNC machine operators for CAM shaft production that includes shaft shaping and cutting process, tool setup, cutting material and programming of CAM shaft dimension.

• Developing CAD models using CATIA V5 and AutoCAD 3D models, prototyping foot brake system designs and checking the quality of design using Ansys software after eliminating the necessary parts.

• Calculating the overall cost of production, and the cost savings achieved by implementing the production design changes. Project Outcomes:

Design improvement and cost saving: Developed a structural change in the design of foot brake system and mounting process which reduced overall cost per unit by 10%.

Implementing Value Engineering: Analysed the value of 10 components in the foot brake system, and of the steps in the production process, which reduced bottlenecks and saved ~$10K on overall production costs annually. Project Name: Analysis of Ammonia production process AUG 2017- NOV 2017 Southern Petrochemical Industrial corporation Pvt Ltd Project Overview: To analyse equipment and processes that had been followed in ammonia production and chemical separation, that includes large steam metallic boilers and valves. Key Responsibilities:

• Replacement of Heating and cooling chambers valves, gaskets that are specified.

• Maintaining shutdown job records that includes efficiency, defect ratio and parts description for boilers and centrifugal pumps, to identify changes required during shutdown process.

• Collecting mechanical information including wear ratio, heating temperature, compression ratio of heat exchanger tubes and valve placements, to assist chemical engineers achieve ammonia production targets through analysis of the process. Project Outcomes:

Proposal of new method: Proposed new production method (Haber process) and prepared a detailed report on the implementation process and benefits of ammonia synthesis, to assist the Production Engineer optimise the Ammonia production process.

Reduction of defects: Developed an improved shutdown and maintenance schedule to minimise production delays and disruptions, which included regular shutdowns, cleaning of parts, and replacement of filter

Personal Details

DATE OF BIRTH: 01-March -1996 LANGUAGE KNOWN: English and Tamil ADDRESS : No.10 Brammaputra street, Ganga Nagar,

Madipakkam, Chennai -91

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