Product Design Catia V5

RAKESH UDUPA

Troy, MI-*****

Mob +1-248-***-****

Email: ********@*****.**.** ; ********@*****.***

Linkedin:- www.linkedin.com/in/rakeshudu

SUMMARY

** ***** ** **** ********** in Product Design, Development & Manufacturing of Automotive components in Exterior, Interiors, Chassis, BIW in Catia, Enovia/Teamcenter, 3DX.

Worked for OEM’s like Honda, Lucid, SAN Motors & Tire 1 experience from Denso, Magna International, Webasto, Gecom, Jac Products, Arvin Meritor.

Have worked in Europe and USA, served as onsite co-coordinator and managed team.

Effective communication & meetings with Customers, Supplier, cross functional team for progress, Problem solving/project execution. Coordinating with Inter team & Offshore team for executing projects.

Domain Expertise: Automotive Exterior (Mesh/Grills, Fascia/Bumper products), Interior (Dashboard

Insulator & Console), Chassis & BIW.

Expertise in New product development (NPD), Concepts, Design & Development, Problem solving, Brainstorming for different project needs. Worked on Plastics, Sheet Metal, FRP, Machined components.

Experience in Styling/Class-A feedback to Styling team with issues and suggestions. Analysis on Crown,

Homologation, Parting line visibility, thick & thin sections, unfeasible tooling condition, DFA/DFS.

Recording & resolving Initial Tool run for sheetmetal parts, Fastening, Identifying/Track/Resolve Build issues, Jira for ECR, Quals, Deviation Requests, Root cause analysis, getting scan reports, CAE, DVP reports.

Worked extensively on VA/VE for cost reduction programs on Automotive HVAC.

Experience of Project planning, estimation & scheduling.

Lucid Motors (Via LTTS, in Michigan-USA) OEM Aug 2024-Dec2024.

Role:- Sr. Design Release Engineer.

Responsibilities:

Engineering Rear Fascia, Exterior Parts.

Maintain - engineering and program documentation (i.e., DFMEAs, DVP&R, timelines, open issues, with JIRA creating ECNs/ECR & DCRs, Deviation Req, Quals).

Driving Supplier meetings, creating MOM’s. Issue resolution with Cross functional team.

Supporting Build, Issue tracking & resolution. Working on, Craftsman targets, dimensional & CMF. Problem solving, Ecube analysis, Making Gauges, Scans, Decision Matrix, Root cause analysis, Saleability, Serviceable parts. Providing SPC points, SCAAF checkpoints.

BOM with maintaining color matrix, Take rate, ICA & PCA, Work Instructions.

EV SUV car parts include- Fascia- Upper & Lower, Gap Bracket Center and sides, Tow Covers, Diffuser.

Using 3DX.

Magna International (Via SATVEN, in Michigan-USA) - Tire-1 Nov 2018 - Jul 2024.

Role:- Sr. Design Release Engineer.

Responsibilities:

Exterior Parts Designing, Concept development & Coordination. Class A evaluation & Feedback.

Worked on End to end Ford projects for -U55X, U71X, P800 from start to release and Change Notice.

Concise Design Release summery include:

Using Class A, Creating Master sections to evaluate Part packaging and Fastening feasibility.

Creating rough 3D Concepts/Proposals to understand the shape, packaging, DFM, DFA, Process, sequence.

Class A Feasibility and Feedback on Draft (different for Grained, Painted parts etc), Possible Parting line,

Crown, Homologation, etc.

Background/Surrounding parts retrievability & traceability, packaging

Designing Parts on Design Standards, Packaging, DFM, Tooling, DFA, DFS, Assembly sequence, Load

study, Process, Driver Tool clearance and provisions etc.

Understanding CAE Analysis report and brainstorming to get corrective actions/Counter measures.

Attending Customer, Supplier, Tool shop meetings to discuss on issue escalation & resolutions and team alignments.

Packaging or Mounting ADAS & supplier parts into Fascia assembly like Parking sensors, Radars, Reflex, BUNA, Antenna, Harness, WAL etc.

Design Validation, Quality checks, BOM creation, supporting work on DVP&R. Data Management in Teamcenter, Centro.

Extensive design activities on: Fascia, Rear Upper & Lower Fascia, Energy absorbers, Sill/Isolator bracket for Front & Rear, Rear Step Pad, Tow cover, Hitch Cover, Chrome parts.

Other activities include- Coordinating with team for Design direction & Delivery planning, Concept Development, Problem solving, Tooling feasibility study, Bench marking, Pendulum setup & Impact study, DFM, DFA, DFS, Loading study, Product clearances, Resolving assembly defects & packaging, Team Center data management, Parts/ Products Drawing release, Executing Change Notice.

Webasto Roof system (Via Satven in Michigan, USA ) - Tire-1 Jun 2017- Jul 2018

Role:- Sr. Design Engineer.

Responsibilities:

Subject Matter expert of Rollo assembly.

Parts include Fabric, Plastic Bearings (Structural-PBT), Splitter, Tension & Extension bars, Shaft, Electro static discharge element, etc.

End to end of Rollo assembly design. Creating Master Section to Design Release.

Creating & maintaining BOM.

Designing technicalities for Rollo assembly include Hard stop, Couplers overhang, Fabric tension and sag, Fabric Rolled and developed length calculations with min clearances at both the conditions, Attack angle.

Redesigning Plastic Housing, Designing Metal Cable routing design considering DFM, Corner piece.

PDM Management. Maintaining color complexity.

Making 3D Proto and testing.

DENSO Automotive Deutschland (Via Satven, in Eching, Germany) Tire-1 Jul 2014- Feb 2017

Role:- Sr. Design Engineer.

Responsibilities:

Automotive HVAC components like Motor Holder, Blower Cases, Distribution Cases.

Improving Motor Holder shape for Noise reduction & better flow.

Changes to Cooling channel in Blower case & Motor Holder for better distributed cooling to Motor & electronic pins.

VAVE by reducing screwing, improving Ribbing to reduce material thickness, Motor Wire length reduction. Project cost reduction based on Tooling, Parts, Material or Process.

R&D for improving Motor Cooling, Easing the PTC installation techniques. Reducing Sliders to reduce costs.

Worked on prototype models to optimize Air flow for Motors, Reduce noise.

Cable clippings for ease of Assembly & serviceability during blind operation.

Honda R&D America inc. (Via L&T, in Ohio, USA).-OEM Feb 2011-Apr 2014

Role:- Industrial Engineer

Responsibilities:

Extensive work on designing BIW-Floor (Under Body) for SUV. Worked on Underbody- Floor and Exhaust tunnel area. Worked on designing Floor Structure by formability and different Fastening techniques like flow drill screws, Welding (Spot or MIG), Mechanical Fasteners.

Worked on Enlarging Rear Bed (pick-up box structures) & Trunk redesign for a pickup truck (Tire trey, Pan, Cross member, Bed Pivot). Packaging Design changes to existing background structural parts & welding’s. Evaluating dynamics parts & positioning retrievable parts to meet human reachability. Creating BOM of changes.

Sedan Sports Car Trunk design. Volume created with Golf bag & luggage bag- loading, unloading & packaging. With this data, opening of the Trunk was created. Rest designed with packaging the surrounding parts. Carpet is designed to the Layout.

Designing Mesh lower & Front Bumper for a Pickup truck, Designing Dash Insulator & Carpet (Trims), creating RPT parts (Rapid prototyping), Braces design for improving Vehicle performance based on CAE results. Experienced in Fog Lamp mountings on to the Lower Bumper.

Air Duct Designing, Packaging for smooth air flow for least decibel levels.

Layout creation to study the kinematics of parts in Trunk lid.

Model Based dim (MBD), FTA are extra skills used in Catia for scope of work.

Arvin Meritor Pvt. Ltd., Bangalore. Tire-1 Sep 2009-Aug 2010

Role:- Design Engineer III

Responsibilities:

Packaging, Designing, concept development of different Sunroof modules like, Frame, Carriage, Glass Panel, Rollo blind assemblies.

Creating 3D & 2D with mentoring a 2 member team for Sun Roof design for a Parent company in Germany.

Providing project updates to the Management in a weekly team meetings.

Interacting with the coordinator at Germany for work related activities.

Creating Layout Drawings for the Sun Roof. Implementing GD &T. Creating 3D models R&D changes.

Use of Kinematics module in Catia for Analyzing mechanism of the parts in Sun Roof.

HCL Technologies Ltd., Bangalore. Dec 2006 to Jul 2009

Role:- Design Engineer (Member Technical staff)

Responsibilities:

Worked as a team mentor & member (with 6 member team) for a Aero structural project with “Alenia Aeronautica”.

Managing project deadlines, Issue tracking-Used PM tool to track the Deliveries & Reworks, Project updates to management, Documents recording (from Customer, Suppliers, Design Team, Management, Concepts/Proposals, CAE, Tooling, PDM etc) and Traceability. Mentoring Teammates on structures of an Airplane, DFM of sheet metal design.

Coordinating with Inter team for executing different projects activities like Packaging, Technical requirements, Deliveries, issues sharing.

Structural parts predominantly Sheet metal or Aluminium castings & machi. Knowledge of Manufacturing is prime need. Trained on Manufacturing requirement, GD&T.

Experienced in Cockpit, Center Fuselage, Rear Fuselage, Empennage, MLG, Wing, Doors. NMG-Surface is used as Input. Redesigning parts to optimize the assembly for ease of DFM & DFA. VA/VE for certain assemblies as per Customer.

Interacting with clients/Customers (Italians) for any Queries and issue resolutions.

Tools used-Team Center (Enovia) for PLM/PDM, Vis Mockup & DMU for viewing large assemblies.

RADEL ATG Pvt. Ltd., Bangalore Mar 2006 to Dec 2006

Role:- Design Engineer

Responsibilities:

Worked on Designing & manufacturing for secondary Aero structural component.

Quotes, Estimation & Costing for the upcoming projects in terms of time required, manpower required manufacturability, suppliers.

Design Validation, modeling & redesigning of secondary brackets for electronic components of a Aeroplane. Follow up activity with Vendor in manufacturing of the parts up to assembly.

NPD:- New product development of an Plastic cabinet from generating Class A to detailed design of internal parts. The cabinet is modeled by iterations to get the aesthetically pleasing casing for a musical instrument, Squeezing it to the smallest limits by packaging. Handmade Prototype of thermocoal made for visual Aesthetic looks & feasibility study.

Detail Design of each parts for Tongue & Groove locking of 2 halfs, Speaker mounting, Battery compartment, Push button & PCB mounting, Servicability was carried out with DFMEA and VAVE.

Creative ideas for Battery door locking, Speaker & PCB mountings.

Developed a Tool concept for Pin bending fixture & a concept for a 3 direction traverse of Veena (Musical instrument) Bridge with simple & cost optimized manner. Reporting to the Director for all activities.

Interacting with Suppliers for Secondary parts Quality & deliveries.

Underwent Training on Manual Designing parameters of components for structures of an Airplane.

SAN MOTORS Ltd. Bangalore, OEM. Aug 2005 to Mar 2006

Role:- Product Engineer

Responsibilities:

Development project of redesigning Chassis (Rolling Chassis) to mount Upgraded Engine (from RENAULT to TOYOTA) & allied components.

Worked with 2D drawings for Engine packaging, mountings until the engine arrived.

Designed & Packaged Engine mountings considering DFS, DFA, DFM, existing tool requirements etc.

Design modified Fuel tank to mount bigger Fuel Pump.

Design modified & mounted accessory parts like Air Filter, Drive shaft, Wiring Harness, Exhaust Pipe, steering rack mounting, Fuel pump, Bonnet, Gear shift lever mountings, Radiator mountings.

Redesigned Console to fit new Gear Lever position.

Reverse Engineering to get 3D points using Co-ordinate Measuring Machine (CMM).

Handled projects of developing FRP components & Resin Mould Transfer process.

Resolved a reoccurring problem of the carry over dynamic part- Upright (Fork/Knuckle) by deep dive on installed actual car parts.

JAP ENGINEERING, Bangalore, Ancillary to BEL. Jul 2004 to Aug 2005

Role:- Quality Control Engineer

Responsibilities:

Redesigning, Maintaining Process and Quality of Manufactured parts for Offroad truck/Cabinates.

Material worked on includes, Mild steel, HSS, HRLC, OHNS for Sheetmetal, Machined, Castings parts.

Maintaining Quality (Non destructive) of the process for a component based on the value addition,Maintaining Quality (Non destructive) of the process for a component based on the value addition, assembly & customer requirement. In-process inspection to final inspection.

Initial tool (press) run- defects capturing and possible solutions.

Translating complicated blue print drawings into machined output.

Estimating and scheduling of the components based on the output delivery time.

Vendor visit & inspection for the optimum quality of the product.

Preparing RPTIT (Routing Process Tooling Inspection & Testing), PPM rejections using graphs, Cause and effect diagram for major PPM, Pareto Analysis. Implementing Innovative ideas for deliverables.

Additional Tools & Software experience:

CAD: Catia V5- Part, GSD, Drafting, Aerospace Sheetmetal design, Assembly, Volume creation, DMU, Kinematics, Function & Tolerance, MBD, Fit Volume creation, Kinematics (Basics).

UG NX - Part, Drawing & Assembly modules.

Creo - Part, Drawing & Assembly modules.

Familiarity: -Press Tools & Precision Mfg., Jigs & Fixtures, Injection Moulding, Machining processes

Hands on: -MS Office, Visual Mock up, Team center (PLM& PDM), Matrix one, NAVI.

EDUCATIONAL QUALIFICATIONS

Bachelors in Mechanical Engineering, Karnataka, India

VISA: H1B Visa, Approved i140. Currently placed in Michigan.

Contact this candidate