Design Engineer Mechanical

Ram Balaji Kadali – Sr. Mechanical Design Engineer

Mobile: +1-706-***-**** Email: ******.******@*****.*** Cedar Rapids, IA Summary:

Results-driven Senior Mechanical Design Engineer with 14+ years of experience in developing innovative and manufacturable products across consumer appliances, medical devices, healthcare, and electrical equipment. Expertise concept-to-end product lifecycle, with a strong focus on Design for Manufacturability (DFM) and Assembly (DFA). Skillful in leading tolerance stack-up analysis, mold flow analysis, and design optimization to enhance product quality and reduce manufacturing costs. Expert in 3D CAD (Creo, SolidWorks, CATIA), PLM systems (Windchill, 3D Experience), MBD and cross- functional collaboration and team management to drive successful product development. Key Skills:

• Design & Development: Product Design, Concept Generation, CAD tools, MBD approach, GD&T, Tolerance Stack up Analysis, DFMEA, DFM, DFA, Six sigma DMAIC, Prototype builds.

• PDM and PLM systems: Windchill, 3D Experience, Intralink.

• Analysis & Simulation: Mold Flow Analysis, Clearance & Creepage Analysis, Cetol

• Project Managements: Agile, NPI, NPD, Cross-functional Team Collaboration.

• Standards & Compliance: ISO1101, ISO8015, ASME, ISO 14644-1, 21 CFR, ROHS, FDA, GMP, ISO13485, ISO14971, USP Class VI, UL, IEC60068, IEC60601

• Soft Skills: Leadership, Problem-Solving, Cross-functional Collaboration, Mentoring. Professional Experience:

Sr. Mechanical Design Engineer HCL America, Inc. Client: Schneider Electric

Feb 2023 – Present Cedar Rapids, IA

o Led the design and optimization of plastic, sheet metal, and electro-mechanical components for Miniature Circuit Breakers (MCBs), resulting in improved performance and manufacturability. o Successfully addressed critical design challenges, such as resolving assembly issues for Energy monitoring CTs and enhancing the performance of Ground Fault CTs. o Conceptualized and developed a new lockout bracket accessory, aligning with market and regulatory requirements and addressing the unique needs of the smart MCB product. o Provided mechanical design support for new innovative PCB current transformers (CTs) aimed at modularization design.

o Conducted Clearance & Creepage Analysis to ensure product safety and compliance with electrical safety standards.

o Utilized CAD tool Creo and analysis extensions like Cetol to verify component tolerances and minimize manufacturing variations and improve process capability. o Verified the design concepts using rapid prototyping using 3D printing and in-house fabrication. o Collaborated effectively with cross-functional teams engineering, manufacturing, procurement, quality, and close interaction with Suppliers to ensure timely and successful product launches. o Streamlined design changes by effectively utilizing PTC Windchill and internal PLM applications, ensuring seamless and accurate documentation updates. o Facilitated smooth manufacturing transitions by generating comprehensive documentation, including technical specifications and component quality control documents.

Sr. Mechanical Design Engineer Capgemini America, Inc. Client: Cytiva Life Sciences (formally known as GE Healthcare Life Sciences) Jul 2018 - Feb 2023 Marlborough, MA o Developed robust design concepts for critical components in bioprocessing equipment, including consumables, single-use platforms, and cell culture systems using Creo and SolidWorks CAD tools. o Streamlined assembling processes and reduced costs by redesigning Impeller and Sparge assemblies.

o Collaborated closely with analysis and automation teams to ensure the successful integration of mechanical, electrical, and control systems.

o Played a key role in product validation and verification activities, including Installation Qualification (IQ) and Operational Qualification (OQ). o Effectively managed engineering changes and maintained BOMs with the 3D Experience PLM.

Mechanical Design Engineer Capgemini America, Inc. Client: GE Healthcare OEC

Nov 2017 - Jul 2018 Salt Lake City, UT

o Designed and developed a multi-product Foot Switch Holder for surgical equipment, resulting in annual cost savings of approximately $200K.

o Prototyping and design verification ensured the viability of the concepts using CAD tool PTC Creo. o Conducted thorough tolerance stack-up analysis and initial mold flow analysis prior to tooling release and communicated with mold vendors for DFM reviews and finalized manufacturing and adhering to stringent FDA design control procedures. o Generated comprehensive 3D models and detailed drawings throughout all phases of the product development cycle.

o Streamlined design changes and improvements by effectively utilizing the Windchill and 3D Experience PLM systems for ECO and ECN processes.

Platform Engineer - Cooktops Tech Mahindra (America) Inc. Client: GE Appliances

May 2016 - Oct 2017 Lafayette, GA

o Designed and developed key subsystem-level components for Cooktop and Oven products, focusing on post-market enhancements.

o Successfully redesigned the mechanical knob for Gas and Radiant electric cooktops to address safety concerns and improve performance.

o Enhanced the aesthetic appeal of the Oven product's HMI display based on consumer feedback. o Supported seamless manufacturing implementation by prototyping and testing chosen design concepts within the manufacturing facility.

o Utilized Six Sigma DMAIC techniques and tools to manage projects focused on the development and continuous improvement of design.

o Ensured design robustness through rigorous validation and verification processes, employing DFM, DFA, DFMEA, and Tolerance Stack up Analysis.

o Collaborated closely with Manufacturing and suppliers to optimize material selection, manage lead times, and ensure a smooth supply chain and process the First Piece Inspection Report (FPIR). o Conducted comprehensive mechanical testing, including Drop, Leak, Sharp Edge, Impact, and Door Slam tests, to evaluate design performance and ensure product safety.

CAD Lead - Refrigeration Tech Mahindra Ltd. & Tech Mahindra (America) Inc.

Client: GE Appliances Feb 2011 - Apr 2016 Louisville, KY o Designed and developed innovative plastic and sheet metal components for Refrigeration products at the subsystem level using Creo CAD.

o Provided critical design support for new market-leading features, including Hot Water Dispensers and Coffee Dispensers, for Refrigeration products. o Streamlined the design release process by efficiently managing Engineering Changes (ECN, ECO, and ECR) within the Windchill and Agile PLM systems. o Generated comprehensive drawing documentation, incorporating GD&T principles per ASME Y14.5-2009, and accurately maintained Bills of Materials (BOMs). o Generated designs with Model Based Definition (MBD) process in Creo with necessary information.

o Actively participated in rigorous design reviews and quality checks to ensure adherence to industry standards and program requirements in collaboration with cross-functional teams. o Played a key role in prototype development, pre-pilot runs, and pilot builds, effectively identifying and resolving potential issues before mass production.

CAD Engineer - Technical Service Designtech Systems Ltd., India Client: ITER

May 2008 - Feb 2011 India

o Developed 3D models and detailed drawings for machined components utilizing the CATIA CAD tool incorporating basic GD&T principles, surface finish specifications, and appropriate tolerances. o Provided critical support to the engineering team in the conceptual design phase of neutral beam components.

o Modified components, assemblies based on the findings of engineering analysis reports. o Conducted rigorous quality checks on all drawings and models to ensure accuracy and adherence to design requirements.

Key Achievements:

• Designed and implemented a multi-product Foot Switch Holder at GE Healthcare OEC, leading to $200K in annual cost savings.

• Optimized assembly processes by redesigning Impeller and Sparge assemblies at Cytiva Life Sciences, improving efficiency and manufacturability.

• Secured the top position in the USA for the Windchill PBOM assessment at Schneider Electric, showcasing expertise in product lifecycle management. Certifications:

• GD&T for Design - Certificate # DESIGNGEKZ0600001027

• Tolerance Stack up Analysis - Certificate # DESIGNGEKZ0700001110 Education:

Bachelor of Science in Mechanical Engineering Acharya Nagarjuna University India 2006

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