RIJUSH MENON

adjyrs@r.postjobfree.com https://www.linkedin.com/in/rijush-menon 609-***-****

PROFESSIONAL SUMMARY:

Highly analytical and detail-oriented professional with progressive internship experience in Mechanical engineering, Project management, Finite element Analysis and Design engineering. Well-rounded mechanical engineer and creative individual with an ability to develop innovative solutions for clients' problems. Instrumental in conducting material design, evaluating new material and in developing effective cost for various projects in adherence to company risk and cost issues. Skilled in analysing project specifications, developing work schedules, and delegating tasks to different teams. Proven expertise in CAD design 3D and Solid Modelling, FE analysis, Simulation, Equipment selection, Sizing, Design, Equipment test design and execution. EDUCATION:

Wayne State University (3.85/4.0) Detroit, MI

Master of Science in Mechanical Engineering Graduated Dec 2020 GITAM University (8.0/10.0) Hyderabad, India

Bachelor of Technology in Mechanical Engineering Graduated May 2018 CORE COMPETENCIES AND SKILLS:

• Advanced knowledge in mechanical engineering, design and development: MS in mechanical engineering with a specialization in Solid mechanics, Machine design and Finite element analysis. Additional proficiency in dynamic analysis of systems, prototype testing and manufacturing, analytical design modeling.

• CAD Modeling and CAE Analysis: Proficient in CATIA and SolidWorks with 3 years of experience in solid and surface modeling, and Finite Element Analysis softwares such as ANSYS, Abaqus and Hypermesh with 2 years of experience in linear and non-linear analysis

• Research and Development in FEA and Crash analysis: Extensive experience in development and testing of various components using CAE softwares. Developed a pressure vessel using the concepts of linear elastic fracture mechanics. Also reduced the stress and kinetic energy of crash impact in Honda Accord using Crash analysis.

• Software and Application skills: Proficient in using Microsoft Office suite (Word, Excel, PowerPoint) and advanced working knowledge of Hypermesh. Certification for Solidworks, CATIA and Matlab from Central Institute of Tool Design.

PROFESSIONAL EXPERIENCE:

Minghua USA, Prototype Builds Engineer Sterling Hieghts, MI Jan 2021 - Present

• Developed product/vehicle manufacturing approaches, design tooling, part timing and program timing.

• Selected fixture design components to optimize assembly and alignment functions.

• Designed and conducted manufacturing and assembly process for Riivian’s Fascia (Front and Rear).

• Supervised and conducted quality checks of the product assembly and improved the process of the manufacturing process by reducing the time.

• Created product detailed documentation to aid the build process, capture traceability and conformity. Ford Motor Company, Vehicle Evaluation Intern Dearborn, MI Sep 2020 – Dec 2020

• Evaluated the total performance (Powertrain, Ride & Handling, NVH, Brakes, ADAS, Human Factors, etc.) of Ford prototype, pilot and production vehicles.

• Performed subjective vehicle evaluations, identified potential issues, investigated problem root causes, and recommended potential countermeasures.

• Conducted Technical evaluation of the test results including risk assessment and derivation of development recommendation.

• Tracked the development status of Ford prototype and pilot vehicle projects.

• Performed vehicle testing on-road, chassis dyno, and at test tracks.

• Planned and executed Design Reviews and Ride & Drives of prototype and pilot Ford vehicles.

• Organized and executed bench-marking activities on competitive vehicles. Rane Madras Ltd., Mechanical Engineer Intern Chennai, India April 2018 - Sept 2018

• Executed best practice and spearheaded various functions including detailed mechanical part and integration assembly design of ball joints, ball stud, bearing, socket and plug using Solidworks for design and test based on ANSI and ISO standards.

• Leveraged professional expertise to develop from concept to schematic to layout and assembly in close conjunction with RF design, mechanical and process engineers. Also, customized the design of the ball joint and improved its functioning by 23%.

• Integrated Geometric Dimensioning & Tolerance (GD&T) for manufacturing and design for assembly.

• Developed DFMEA’s to identify potential failure modes and DVP&Rs to ensure that functional objectives are met by the component design and validation is completed.

• Resolved issues and concerns with cross functional teams including engineering, supply chain, production and service thereby reducing the assembly time by 1.4 seconds per unit time.

• Conducted Mechanical design review with customer which includes detail in dimensional tolerance analysis, basic FEA calculation, DFM and manufacturing assembly flow and fixture.

• Generated ECO’s (Engineering change orders) to release completed drawings and Bill of Materials (BOM). Also, reduced the production cost by 15%.

Indian Society of New Era Engineers, Design Engineer Delhi, India Nov2015 - Oct 2017

• Modelled the chassis and swing arms in Solidworks 2016 based on the minimum requirements prescribed by the client.

• Simulated the performance of swing arms & chassis in Solidworks simulation and ANSYS and obtained reduced stress results up to 23%.

• Improved component designs and defined new design guidelines to improve quality and productivity. The newly designed components were 30% cheaper than the older component.

• Developed complex test plans, procedures, work instructions from client’s requirements DVP&Rs, and FMEAs.

• Generated ECO’s (Engineering change orders) to release completed drawings and Bill of Materials (BOM). Also, reduced the production cost by 15%.

• Deployed in-depth understanding and conducted FMEA and DFMEA and identified the failure modes in the designs, completed fault tree analysis, and developed countermeasures and revised designs to meet updated requirements. Also, reduced the economic costs by 25%.

• Directed a team that stood 7th in the country and received honourable recognitions for the best economical cost report, 3rd place in acceleration test and 5th place in the endurance test. ENGINEERING PROJECTS:

Design of Pressure Vessel: Research Assistant Detroit, MI March2020 –Dec 2020

• Designed the pressure vessel from the given parameters in Solidworks using the techniques of solid modeling, assembly and sheet metal.

• Worked on prototype of new designs, conducted performance analysis prototypes and assembly of product

• Performed the calculations of the pressure vessel parameters using concepts of linear elastic fracture mechanics and then performed the analysis in ANSYS using the concepts of Finite element analysis.

• Complied with Design Control & Stage gate processes while designing prototypes & products.

• Analysed new materials, technologies & processes to evaluate functionality for product development and

• improvement of existing pressure vessel.

• Used the Ashby curve to determine the finest material used to manufacture the pressure vessel and material selected from the curve was 12% resilient than the previous model using the principle of leak before break method.

• The design of the pressure vessel could sustain a pressure up to 12psi.

• The crack life of the pressure vessel was increased by 3%.

• Conducted research on competitor’s performance bench-markings & latest advancements in the industry.

• Created bill of materials for the pressure vessel and reduced the overall manufacturing costs by 27%. Honda Accord Crash Analysis: Student Assistant Detroit, MI Feb2020 - May 2020

• Developed Honda Accord model in LS-Dyna software and ran the analysis of the baseline model obtained from NHSTA.

• Optimize the structural performances by considering vehicle structural architecture and packaging of key components using tools such as LS-OPT/LS-TaSC /HyperStudy /Optistruct.

• Perform detailed post-test analysis and correlate CAE simulations to test results.

• Interpreted FEA results and provided documentation for design, analytical models, design parameters and simulation results.

• Used analytical tools to guide component and sub system design through optimization to meet FMVSS, IIHS, ECE, GB, and other regulatory requirements.

• Provided system level performance specification of active and passive safety systems, translate system performance requirements into component design requirements.

• Eliminated the negative volume error in the model by 30%.

• Used CAE tools to optimize mass for BIW, closures, chassis, battery and other sub-systems.

• Developed vehicle and component structural models for predicting component failure, impact, vibration, fatigue performance, and other cases.

• Diagnosed the design defects of the bumper and windshield and improved the design by 16%.

• Performed the dash intrusion for the vehicle and achieved reduced stress levels by making necessary changes in the design.

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