Principal Mechanical Engineer
Methode Electronics, Inc.
Total years of experience :13 years, 3 Months
Currently performing Lead role in the engineering department of an Automotive Tier 2 organization complex insert molding division. Experienced in handling Power train electrification design projects. The responsibilities are
Design of complex lead-frames, connectors and busbars for Automotive Power Electronics systems. Design of pre-mold, over-mold and stamping for leadframes used in the power trains of EV and HEV Design of measurement fixtures for plastic and sheet metal components for CTQ dimensions Review with molding, stamping and production team for DFM and continuous improvements. Review RFQs from different Automotive OEM customers and prepare technical review documents and DFM/DFA proposals for the bid package Co-coordinating with sourcing team for off the shelf parts and manufacturing of non-standard parts thru sub-suppliers and actively involving in supplier development for newly engineered components. Review insert mold and over mold drawings/ defining specific surface treatments for stamping Design transfer to production and vendor management, supplier qualification, supplier validation plan and report review. Engineering activities monitoring thru weekly status review meetings. Review the BOMs and coordination with manufacturing/purchase for ERP updating. Review of design concept drawings and 3D models and obtain the approval from customers. Change management and follow ups till the implementation Initiating DFMEA with the core team and plan the risk mitigation at the design phase. Providing inputs to Manufacturing and Quality engineers at factory for PFMEA and control plan .
- I am part of a team which does engineering and design support for medical devices (infusion and orthopedic product lines).
- Conducted a feasibility study on laser etching on the products like medical implants and surgical instruments for CE marking on products.
- Conducted engineering analysis to prove the extra engraving on the product doesn’t affect the strength.
- Provided engineering solution for leak detection in a IV fluid warmer in a dialysis device.
- Reviewed project specifications, datasheets and bid documents to establish customer requirements.
- Assisted technical managers in concept evaluation for NPD projects using various quality tools.
- Reviewed existing design and proposed new designs which compiles to RoHS.
- Designed electromechanical systems assisting small motors and conducted engineering calculations.
- Suggested engineering changes and replacements for the components of a body fluid warmer.
- Conducted a competitor product study for infusion warmers in US market for product up-gradation.
- Redesigned the injection molded casing for the control unit of a patient drug delivery system.
- Conducted manufacturability and cost analysis on injection molded parts.
- Updated the engineering changes of orthopedic implants and surgical instruments in PLM.
- Done a case study on various manufacturing and finishing process included in trauma implants.
- Updated drawings and 3D models of orthopedic human implants using ProE and Creo 2.0 Parametric.
- Managed iterations of drawings in Windchill (PLM for Creo)
-I was part of a team does engineering of Gas Turbine Power Plant Package systems for power generation and offshore oil& gas mechanical drives.
-Prepared and owned many technical reports and files related to design, regulatory and quality.
-Prepared bill of materials and datasheets as per CAD drawings.
-Reviewed project specifications, datasheets and bid documents to establish customer requirements
-Reviewed electrical control systems design/engineering in the system/subsystem/auxiliary system level.
-Redesigned/re-engineered Gas turbine intake air augmentation unit.
-Complied/Updated technical files, Hazardous Area indication drawings, F & G Layouts.
-Prepared reports of weekly project status and managed work and manpower.
-Managed PLM, proposed changes for Design direction, Spec, cost.
-Constantly interacted with US customer to understand the requirement and to update project status.
-Done engineering change management followed by ECR &ECO in Rolls Royce engineering portal.
-Reviewing the documents of components and Energy package and certification as per Gas Industry Standards, Release the engineering changes in engineering portal.
-Reviewed and revised the certification requirements for piping components as per PED (99/36/EC).
-Conducting Hazard Cause and Effect analysis and functional FMEA for various subsystems.
My activities were,
-Developed and engineered a handheld rugged device for military application (Users - Indian Army, Paramilitary forces)
- Worked in new product development from development, product engineering(value engineering and costing) and till manufacturing.
-Worked in Electronics Packaging (Both mechanical and thermal) of military devices.
-Developed/engineered electro-mechanical modules like switches, motors, connectors, conduits and sensors for specialized military applications.
-Was part of a mechanical designer team engineered the prestigious project SAMVAHAK Ph2.
-Designed and engineered various mechanical handling mechanisms for a military base station.
-Worked with a group of CAD engineers for engineering change executions and new CAD model creation in SolidWorks and AutoCAD.
-Done value engineering for various mechanisms developed and achieved a marginal cost reduction.
-Done various engineering design calculations for the mechanisms, plastic and sheet metal part development.
-Co-coordinated with Rapid Prototyping facility and vendors for the first time production and design verification.
-Conducted various environmental tests as per MIL-STD for compliance verification.
-Compiled various mechanical test protocols, manufacturing and assembly instructions.
-Conducted design FMEA and DFM&A analysis for new designs.
-Attended design reviews and presented to cross functional design review committee.
B.E-MECHANICAL ENGINEERING
Science with mathematics and biology
