Mechanical Design Engineer
Alfanar Electrical Systems, Riyadh KSA
Total years of experience :13 years, 6 Months
• Design and development of :
Distribution boards & Circuit breaker enclosures as per IEC/BS Standards.
Sheet metal enclosures & Plastic parts for insulation.
Components: Hinges, Latches, Gaskets.
• Concepts generation for product feature enhancement based on customer feedback.
• Mechanism design for assembly verification and tolerances study in CAD.
• Product feasibility & market response study for new products through prototyping.
• Cable routing design for distribution board using Creo Cabling.
• Cost vs. functionality study & redesigning existing products for cost reduction.
• Manufacturing drawing and bill of material creation.
• Product risk assessment through DFMEA.
• Developing test plan to ensure reliability of product & conformity with standards.
• Project management and keeping track of deadlines using MS project.
• Establishing the specifications for the new material procurement for supply chain team.
• Cost estimation & design proposals for new products based on inputs from customer.
• Interacting with Marketing and Onsite team to collect the specific market requirement.
• Vendor development & evaluation
PROJECT HANDLED:
•Led the Project to develop new range of Circuit breaker enclosure with IP55 & IP65 protection.
•LV standard and non-standard distribution board for KSA, OMAN, KUWAIT Market.
•ROOM DB’s 1 PH & 3PH with MCB & Contactor combination for hotels.
• 1PH Consumer Unit for Contactum UK - developing new design, cost reduction for existing design, improved internal and external aesthetics & 3PH DB’s as per BS 7671 Amendment 3.
Product design - Air Intake Manifold, Air intake Duct for German Customers & Indian customers.
•Extensively used Catia V5 for Modeling and surfacing to make design & tooling proposals for customers.
•Creating of Weld Bead for vibration welding.
•Splitting of parts for tooling feasibility.
•Interacted with French Design team and customer to freeze specs.
•Created drawing for manufacturing, Project report and proposals.
Projects :
Tata Motors : Design of 3 Cylinder AIM.
-Concept generation for manufaturing
- product Feasibility study,
- Tooling proposals
Volkswagen :
Design of Air intake ducts,
-Part tooling feasibility study
-Part splitting for Vibration welding
Product Design: Mirror assembly (IRVM, ORVM, F-Type & C-type, and Motorized Mirror), Plastic & sheet metal Parts, Mirror Housing as per AIS standards for Ashok Leyland & Tata Motors.
•Rapid prototyping for verification of Assembly and customer approval.
•DFMEA, PPAP, APQP.
•Designed Gauges and Fixtures for Mirror Assemblies.
•Prepared of Technical Datasheet for Quotation.
•Studied FOV (Field of Vision) for different mirrors.
•Implementation of ECR/ECN.
ASHOK LEYLAND -
1. Design of ORVM (Main Mirror, Wide Angle Mirror, Proximity mirror. (Mirror Housing, Mirror Assemblies, Mountings).
2. Design of Gauges and Fixtures for Mirror Assemblies.
3. Design of Bumper View Mirror - Concept for mounting, Housing, Mirror Assembly, Vibration Analysis, FOV study.
TATA MOTORS:
• COMMERCIAL VEHICLE:
1. Design of Rear View Mirrors “Housing, Mountings, Assembly”.
2. Kit Assembly for Mirrors. (F-Type, C- Type).
• Feasibility study & Process assumption.
• Plastic Product design.
• Conversion of 2D into 3D.
• Design of Sheet Metal Components and sending it to Manufacturing Department.
• Collating product specifications & designing and modifying / upgrading existing designs.
• Modification in the existing models to reduce price value.
• To Co-ordinate with Customer.
• To visit customer for clarification of drawing specification.
Projects :
HERO MotoCorp- Onsite Deputation from Aug 2011 to Dec 2011.
Design of Two-Wheeler Body Parts (Plastics).
1. Design of Shroud.
2. Design of Inner Shroud.
3. Design of Rear Cowl.
4. Design of Lower Cowl.
KRONE, GERMANY - Agriculture Machinery
(Part Modeling, Surfacing, Modeling, Sheet metal, Assembly, Drafting in Catia V5)
KARLMAYER, SWITZERLAND- Textile Machine (CATIA V5).
Re-mastering of sheet metal, casting, plastic, machined components and assemblies.
VALEO: Design of Steering Column Casing in CATIA V5
Bachelor in Mechanical Engineering - 2006 - 2010