Plastic Part Design Engineer

SARTHAK RAJARAMJI KHAMKAR

Ann Arbor, MI +1-929-***-**** ********@*****.***

EDUCATION

University of Michigan, Ann Arbor, MI

Master of Engineering in Automotive Engineering; GPA: 4.0/4.0 (Aug 2022 – Dec 2023)

Relevant Coursework: Automotive Body Structures, Design for Manufacturability, Vehicle Dynamics, Lean Principles and Scientific Thinking, Design Quality: Six-Sigma, Smart Manufacturing Systems, Control System Design and Analysis. Vellore Institute of Technology, India

Bachelor of Technology in Mechanical Engineering; GPA: 8.82/10 (Jun 2019)

Relevant Coursework: Strength of Materials, Tool Design, Advanced Manufacturing, Operations Research, Tool Design, Manufacturing Automation, Rapid Prototyping technologies, Facilities and Process Planning, Theory of Machines. TECHNICAL SKILLS

Problem Solving: DFM, DFA, FMEA, GD&T, FEA/CAE, 5S, Kaizen, Product Development, System’s V, PDCA Software: Siemens NX CAD, Teamcenter PDM, CATIA, Solidworks, Ansys, DFMPro, Carsim, GAS, MS Office. Programming: MATLAB / Simulink, Python, C.

Manufacturing Processes: Injection Molding, Sheet metal Stamping, Metal Casting, Thermoforming, Carbon Fiber Reinforcements, Vacuum bagging, TIG Welding.

WORK EXPERIENCE

Renault Nissan Technology and Business Center India (Jul 2019 - Jul 2022) Role: Design Engineer. Collaborated with CFTs and suppliers to design and develop Body Side and Roof Interior Trim parts. Nissan Altima (L42T) – Digital Phase

Spearheaded the master section creation of A, B, C pillars, front and rear kicking plate, dash side trim, and child anchor cover while ensuring 100% adherence to packaging, ergonomics, tooling, manufacturing, and assembly requirements.

Provided styling feedback to enhance functionality of parts and drove development of 3D design proposals of above 7 parts.

Conducted benchmarking studies of competitor products, analysed, and effectively implemented strategies, resulting in improved product performance and part cost reductions up to 50% at times.

Consistently monitored, CDS documents detailing costs associated and DCS documents outlining design specs of 7 parts.

Conducted comprehensive studies on digital ergonomics evaluations, fit and finish, tolerance stack-up and buzz-squeak-rattle conditions, ensuring that all parts were of the highest quality and met performance standards of Nissan. Nissan Rogue (P33A) – Production Trial Phase

Implemented a Siemens NX Macro to detect protrusions (FMVSS201/ECE21) on trim parts, resulting in a 70%-time savings.

BOM Management: Dealt with 36 variants for 5 functions with ~10 different specs across more than 100 application models. Maintained precision and dependability of the part list management system, making it the standard for all related tasks.

Q-base study: Scrutinized over 20 Q-Base (issues reported) and formally design released parts for 5 functions in association with supplier after implementing the effective countermeasures for the issues. ACDEMIC PROJECTS

Analysis and Redesign of Meat Grinder.

Studied product and functional analysis, DFx, to reduce overall part complexity and part count of the assembly.

Cost reduction per assembly of $2.08 and $1.64, respectively, was realized by evaluating DFA and DFM. Developed a sustainable product concept and secured annual savings of $186,000 in manufacturing the meat grinder. Thin-walled Motor compartment Rail section.

Created rail section to meet moment of inertia criteria of 2*e7 mm4 while meeting spatial, manufacturing constraints.

Attained structural axial and bending load requirements with FOS of 2 using Geometric Analysis of Section (GAS). Designed & Fabricated Formula Student Car to Participate in Formula SAE Australasia, 2017.

Lead Chassis / Roll cage and Body Works department of 7 members to design and manufacture a tubular space frame chassis and body works for #ZFR05, while complying to Formula SAE rulebook, achieved 10% reduction in weight compared to previous version of vehicle #ZFR04.

Developed new concept of engine mounts using steel-tubes and PC reducing up to 65% of vibration transmission to driver cabin.

Leveraged Ansys for comprehensive CAE analysis of modal analysis, torsional rigidity, and frontal crash scenarios; conducted laboratory testing for verification and obtained 10% offset in lab and simulation results.

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