Mechanical Engineer
Resume:
HARSHA KUDIGRAM
LE CLAIRE, IA, USA 52753
*********@*****.***
SUMMARY
Mechanical Engineer with experience managing the fire protection program at a large Nuclear Power Plant. Project Management Experience executing CAPEX projects in the Aluminum processing Industry. Experience in the FAA Certification process. Aerospace experience reviewing designs and test procedures for adherence to Industry and Military standards such as NSF,ASME Y14.5, SAE(AS/AMS), RTCA DO-160 and Federal Aviation Regulations such as FAA 14 CFR Part 25. Engine Rating Development Experience on Caterpillar Natural Gas and Dual Fuel Engines including engine performance analysis and calibration. Knowledge of Diesel Engine Fuel Systems including High Pressure Common Rail systems and Fuel Filters. Knowledge of DFSS tools (Six Sigma) and Continuous Improvement Processes. Experience in prototype and production component development using FEA and 3-D CAD. Knowledge of Aerospace Environmental, Vibration and Shock Testing. DFSS Green belt and Lean Manufacturing Training. Finite Element Analysis (FEA) experience including stress, modal and bolted joint analysis of engine components and subsystems. Knowledge of Corporate Financial Reporting and Managerial Finance. Experience working with PLM/ERP and requirements management systems (DOORS) software. Commercial refrigeration experience. Experience working in an MRO (Maintenance Repair Organization) environment. ACCOMPLISHMENTS
• Improved the site Fire Protection Program Health and program documentation. Managed the programs team and provided support to the site during outages. Interfaced extensively and provided support to external auditors, regulators and insurance organizations during audits.
• Managed projects to introduce new capital equipment for Heat Treatment Furnaces. Developed technical solutions to improve equipment reliability and address product failures
• Specified and introduced new temperature control solutions to improve food merchandiser performance and ensure regulatory compliance.
• Developed an alternate conformity process for qualifying CDS (Centreline Drogue System) components for the US Airforce KC-46 Supertanker. Created a new ATP (Acceptance Test Procedure) and helped design fixtures to implement this approach.
• Developed multiple ratings for Caterpillar Spark Ignite Natural Gas Engines resulting in approximately Two Million Dollars in Revenue for the Division.
• Developed new emissions recipes/calibrations and key engine protection and load rate control strategies to help Wabtec win Multi-Million Dollar Contract with Russian customer for Locomotive Diesel Engines.
• Developed and implemented algorithms to convert Coons-Gordon surfaces to NURBS at Iowa State. Contributed software for a peptide and protein spectra calculation package developed at Iowa State University. TECHNICAL SKILLS
• Languages: C.
• Engineering Software: Solid Works/ Edge, Autodesk Inventor, AVL Concerto, Creo, Pro/Mechanica, DOORS
• Project Management software: Excel, Innovia, Windchill, Finario, Oracle ERP, Maximo.
• Certifications: PG-14(Fire Protection qualification), VT-2 (Visual Leak Detection) EDUCATION
Master of Science, Mechanical Engineering, Bachelor of Engineering, Mechanical Engineering Iowa State University, Ames, IA Bangalore University, Bangalore EXPERIENCE
VISTRA CORP IL
Power Plant Engineer 2025- Present
Responsibilities include identifying areas for improvement and collaborating with external business partners/service providers to execute the business plan and implement a comprehensive fire protection inspection and testing program.
• Plant Operations: Monitor and analyze plant performance, ensuring compliance with operational standards and regulations.
• Maintenance Management: Develop and oversee maintenance schedules for equipment to minimize downtime and ensure efficient operation.
• Performance Optimization: Identify opportunities for process improvements and implement changes to enhance efficiency and output.
• Environmental Compliance: Ensure the plant meets environmental regulations related to emissions, waste management, and water usage.
• Collaboration: Work closely with other engineering teams, operators, and management to achieve operational goals.
• Reporting: Prepare and present reports on plant performance, maintenance activities, and compliance status.
• Project Management: Lead or participate in projects related to plant upgrades, retrofitting, or new technology implementation.
• Technical Support: Provide engineering support for troubleshooting and resolving operational issues.
• Safety Protocols: Promote and enforce safety practices within the plant to protect personnel and equipment.
Constellation Energy, Cordova, IL 2022-2024
Senior Engineer – Fire Protection (Certified)
• Maintained configuration control of the fire hazards analysis and reactor safe shutdown analysis. Evaluated the technical acceptability of proposed changes on the approved fire protection program and determined whether proposed design changes could be implemented without prior NRC (Nuclear regulatory commission) approval. Evaluated the impacts of changes to the combustible loading calculations on Fire Protection Program Requirements. Performed NFPA code design review to resolve NRC questions. Provided support and managed the Programs team during outages. Prepared the Program Health Report and drove improvements to fire protection program health.
Arconic, Davenport, IA 2021-2022
Staff Engineer
• Provided support and leadership to the Furnace Quality Assurance group in the Central Maintenance Department at Arconic. Utilized project management tools to successfully manage and execute sustaining and new capital projects. Coordinated all phases of the project from scope development, specifications, bid solicitation, design, installation and project closure. Managed external vendors and contractors providing design, material, installation and other support functions. Provided technical solutions and guidance on design, process and application issues
HillPhoenix Inc, Keosaqua, IA 2019-2021
Senior Product Engineer
• Lead projects to design and improve new and existing Commercial Refrigeration, Food storage and Display Equipment using CAD tools such as SolidWorks. Conceptualized and implemented improvements to existing product to improve performance and for regulatory compliance. Worked directly with design and production engineers to resolve manufacturing issues through root cause analysis. Partnered with suppliers, designers and purchasing to evaluate component alternatives that could be integrated into existing product to improve quality or reduce cost. Participated in continuous improvement activities to improve process capability. Mentored junior level engineering staff.
Cobham Mission Systems, Davenport, IA 2015-2019
Senior Mechanical Engineer
• Lead projects to design and improve new and existing Aerial Refueling (CDS) components and Test Procedures. Supported Multi-Disciplinary teams as a technical lead to design, integrate, improve and qualify new and existing products and components. Supported component and system level testing of Aerial Refueling components prior to installation on the Boeing KC46 Supertanker for the US Air Force. Supervised technicians and Junior Engineers in the development of test Fixtures. Ensured Customer (Boeing/USAir force) and FAA product requirements were correctly interpreted, met and verified. Supported Aerial Refueling Component suppliers in FAA conformity activities for the Boeing KC-46 Supertanker. Conducted Root Cause Analysis to troubleshoot test failures. Participated in CI/Kaizen activities to improve company business processes. Participated in supplier and test house selection activities including assessing technical capabilities and reviewing quotes.
Caterpillar, Technical Centre, Mossville, IL 2013-2015 Senior Performance Engineer (Performance Analyst)
• Lead Multiple Rating Development projects for Caterpillar Natural Gas/Dual Fuel Engines. Developed Engine Performance maps (AFR, Voleff, Fuel...) that met Performance and Emissions targets. Provided leadership and direction to operators, overseas partners, control and test Engineers to ensure deliverables were met in a timely fashion. Prepared Contracts, Estimates, Test Instructions, and conducted Data Analysis using in house and industry analytical tools. Prepared formal presentations (Rating Reviews) of test results and presented it to process partners and other stakeholders.
• Designed Hydraulic Valves, Motors and Structural Components for Caterpillar Excavators and Wheel Loaders at Joliet and Aurora. Assisted manufacturing in resolving production issues by redesigning structural components and conducting finite element analysis. Wabtec, Erie, PA 2011-2013
Lead Diesel Engine Performance, Emissions & Fuel Systems Engineer
• Lead Diesel Engine performance development activities towards achieving locomotive emissions requirements at the lowest possible fuel consumption. Activities included writing test requests, coordinating tests, analyzing test data, reporting on results, making recommendations and working with the engine development lab to ensure the data quality of the tests. Developed new load control and engine protection strategies on unique applications for International locomotive customers. Optimized engine recipes using modeling results to meet international emissions regulations. Created Control Spec documents (ICD) to communicate the requirements of the engine to other groups. Applied Six Sigma Process Rigor in developing and presenting solutions to improve the quality of the output. Communicated project status, schedules, upcoming deliverables and technical solutions between various teams and stakeholders both national and international. Methods of communication included but not limited to the design review and tollgate process, emails and team meetings.
John Deere, Product Engineering Centre, Waterloo, IA 2006 -2010 Product Engineer (Fuel Systems)
• Analyzed warranty claims related to fuel systems on John Deere engines. Worked with different functional groups within the company and outside suppliers and dealers to resolve customer complaints and reduce warranty through failure analysis including the assessment and disposition of non-conforming hardware and material. Developed and implemented test plans to determine root cause of failures, validate new solutions and ensure compliance with customer requirements. Supervised technicians in conducting engine dyno tests to evaluate new fuel conditioners to address customer complaints. Supervised and instructed assembly and test technicians in validation activities and provided instruction, guidance, oversight and support to other personnel through utilization of engineering orders, test procedures, purchase requisitions, correspondence and other means. Supervised bench tests to evaluate fuel pump and injection nozzle parameters. Collaborated with marketing and service in developing specifications and managing projects to develop new filter designs for Deere equipment. Coordinated validation activities on a complex fuel system supplier restructuring and outsourcing project using six sigma tools to develop test plans to minimize risk and ensure emission compliance. Work included estimation of project cost and schedule, defining of technical and program requirements, technical liasoning with suppliers and other functional groups. Adecco Technical 2003-2006
Design Engineer
• Design and analysis of power train/engine components and subsystems on midrange engines for the Chrysler engineering group at CUMMINS and on Marine engines for the Power Systems Marketing Division at Caterpillar. Responsibilities included Modeling (using Pro/E/Creo), FMEA and Analysis (FEA). Worked with test engineers in validating designs through vibration and stress testing.
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