Product Design and development intern

KUMAR SAI NIDAMANURI

+1-864-***-**** ********.**********@*****.*** linkedin.com/in/kumarsai-nidamanuri/ EDUCATION

Master of Science in Automotive Engineering Clemson University - ICAR GPA - 3.74/4.0 Bachelor of Technology in Mechanical Engineering Kakatiya Institute of Technology and Science GPA - 3.12/4.0 SKILLS

Technical Skills: High-Voltage wire harness Development, Six Sigma Principles, G.D&T – ASME Y14.5, DFM, DFA, ECR’s, ECN’s, PPAP, DFMEA, PLM, BOM Creation, Quotations, Feasibility Analysis, 3D Modeling, LV 215, LV216 and USCAR Software Skills: Catia-V5, Siemens NX, Autodesk Inventor, Siemens Teamcenter, Excel, Minitab, and MS Office. CERTIFICATIONS

Lean Six Sigma Green Belt (CSSC), Lean Six Sigma Black Belt (CSSC), G.D&T (Linked Learning) PROFESSIONAL EXPERIENCE

Product Development Intern One Mobility Voltaira Mar’24 – Present

• Coordinated 7+ high-voltage wire harness projects from concept design through prototype and into serial production, ensuring 100% adherence to schedule, budget, and deliverables.

• Designed tooling fixtures and components using Autodesk Inventor, and supported in design reviews, drawing validations, and tolerance stack-up analyses to ensure manufacturability and compliance with GD&T principles, reducing iterations by 20%.

• Optimized data retrieval using Teamcenter PLM and supported BOM creation, design feasibility analysis, process planning, and quotation evaluation to ensure cost-effective and manufacturable product solutions.

• Coordinated with cross-functional teams to minimize deviations by 30% in wire harness development to maintain product integrity throughout the development lifecycle.

• Evaluated test data which includes continuity and HI-Pot test results to ensure with functional specifications by implementing inspection gates to address quality inconsistencies, improving first-pass yield rates by 15%.

• Created problem reports, managed ECRs and ECNs to implement design changes and revisions, ensuring production feasibility.

• Supported PPAP documentation for 20+ harnesses programs, by providing design validation data and ensuring process capability. Product Design and Development Engineer Force Racing -SAE Dec’18 – Dec’21

• Led the design and fabrication of SAE vehicles, applying DFM/DFA principles, which improved assembly efficiency by 30%.

• Developed concepts to CAD modeling of vehicle, followed by fabrication processes to ensure 100% adherence to SAE Standards.

• Lead design reviews to reduce interference issues and conducted FMEA to implement design modifications from acquired failures which led to a 25% increase in structural reliability.

• Developed and maintained detailed BOMs with cost calculations and sourcing data, optimizing procurement from 15+ vendors while ensuring material performance and adherence to a $7000/system budget. PROJECTS

Plant Simulation through Siemens Tecnomatix Clemson University Aug’23 – Dec’23

• Modeled a manufacturing plant floor layout design with optimal machines, robots using Siemens Tecnomatix plant simulation.

• Designed a plant layout to accommodate demand fluctuations of 40%, by effectively managing shifts to optimize production.

• Evaluated the cycle time variability, machine downtime and performed OEE, cost analysis, material handling, and shipments costs, which improved the operational productivity through efficient plant layout. Development of Master Cylinder using Composites Clemson University Aug’23 – Dec’23

• Designed master cylinder in Autodesk Fusion 360, reducing weight from 500g to 86.4g using PA66/6T composite.

• Optimized injection molding parameters, reducing melt time from 2.158 to 1.827 seconds and shrinking from 6.584% to 5.399%.

• Achieved FOS of 6.14 to 15 and reduced cooling time from 142.86 to 70.12 seconds, enhancing product and production efficiency.

• Enhanced production efficiency to fifty-one parts per hour, resulting in over 230,000 parts annually by streamlining workflows. Production Takt Time and Cycle Time Improvement FSC cutting tools Jan’23 – May’23

• Designed and simulated a machine layout improvement for machining operations using a cellular manufacturing strategy, resulting in a 12% increase in efficiency and an 18% reduction in waste.

• Applied Lean Six Sigma and DMAIC methodologies to identify process inefficiencies and develop robust SOP’s.

• Improved takt time and optimized cycle time, achieving a 15% reduction in downtime while managing the OEE dashboard using lean methodologies to address and eliminate production inconsistencies by 13%.

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