SUMMARY

• In response to the advertisement you published, I am sending herewith my resume & covering letter for your kind consideration. I am a Sr Design Engineer who holds a Master in Mechanical Engineering, PhD in Engineering & Technology Management (Research: Lean Product Development - Nominated for the best paper of the year award), and a Green Belt (GE & Confidential ) & Black Belt (GEA). I have an excellent experience and knowledge of Designing (NPI) and Manufacturing. Currently, I am working as a Sr. Design Engineer at Confidential. I am a very creative Engineer who came up with many creative ideas (over 50) and designed and manufactured various parts during my Career. Also, I am a DFR (Design for Reliability) Practitioner, and a DFMA (Design for Manufacture & Assembly) Champion to coach Engineers to design for Manufacture & Assembly using Lean Product Development Techniques.
• Extensive Design Experience with excellent Innovative Ideas-introduce more than 50 innovative ideas to upper management (Some of them: Single Serve, cost effective Ice Maker, Link Less Wiper system, and cost effective Automotive AC Compressors assembly)
• Excellent Product Designing & Manufacturing Experience in Appliances Industry, Automotive Industry (Toyota, Ford, GM, Chrysler, Opel, Confidential, Confidential, and NewFlyer Bus Industry), and in Off Highway Industry (Caterpillar, CNH,confidential, John Deere)
• Excellent experience of 3D Modelling of Complex Parts, and preparing detail drawings including applying GD&T using Windchill (Creo), Unigraphics NX, Solid Edge, Solid Works, Catia
• Excellent experience in Electromechanical Component Designs (Auger Motors, Wiper Motors, AC Compressors, Ice Makers, Single Serve Mechanisms etc.)
• Excellent team work experience with cross functional teams
• Excellent experience in FFA using FEA software such as Ansys, Abacus
• Excellent experience and knowledge of Plastics and Metal Alloys

PROFESSIONAL EXPERIENCE

Sr. DESIGN ENGINEER

Confidential, Louisville, KY

Responsibilities:

• Design Electromechanical components such as Auger Motor Assembly, Ice Crusher, Electronic Displays, ice Maker, & Ice/ Water Dispensing Mechanism
• Completed General Electric the first fast work program in time by Implementing Lean Product Development, Concurrent Engineering, and Agile Manufacturing
• Design and coordinate Concept to Production of Refrigerator Plastic, Stamping, Die Casting, and Extrusion parts using Creo software-Never missed due dates
• Designed a Single Serve Mechanism for Refrigerators (for Ice & Beverages team)
• Work in NPI projects (worked in one Mission One Project)
• DFMA (Design for Manufacture and Assembly) Champion to coach other Engineers
• Responsible for DFR (Design for Reliability) Process
• Worked directly with Manufacturing plants and suppliers to Introduce New products
• Work Closely with cross functional team to implement Lean Product Development/DFSS
• Work closely with suppliers to design Plastic Injection Molding, Stamping, Deep Drawing, Extrusion, and Die Casting tools
• Use Concurrent Engineering to reduce lead time and to make Robust Products
• Design integrated injection moulding parts to reduce cost and number of parts
• Designed metallic resin parts-first time in GEA history-$10/part saving
• Introduced more than 40 new Creative Ideas
• Perform Mold Flow Analysis to optimize the parts and find proper gate locations.
• Design cost effective parts to reduce cost and improve quality
• Perform FEA-Structure using Ansys
• Introduced Metal Injection Molding & Thixo Molding Technology to GEA
• Help engineers to apply proper GD&T, perform Mold Flow Analysis.
• Perform reliability and validity tests & coordinate Design for Reliability process (DFR 10 Steps)-Failure Investigation & Corrective Actions
• Possess 4 patents, and 6 Pending patents

Sr. PROJECT ENGINEER

Confidential, Bloomington, IL

Responsibilities:

• Designed Vacuum Cleaner Parts (Plastic/Metal) for Injection Molding, Gas Assist Injection Molding, Stamping, and Thixo Molding using Unigraphics NX
• Selected suitable Stainless & Plastic materials to reduce cost and to improve quality
• Worked directly with Manufacturing Plants to Design Functional Fixtures and Gauges
• Prepared detail DWGs and Implemented GD&T
• Introduced Self Cleaning & Germ-Killing Vacuum Cleaner using Nano TiO2
• Submitted more than 10 new Ideas to improve company products, and to reduce cost
• Prepared Concept designs for new Generation Vacuum Cleaners
• Performed Tol. Stack-ups and Classical Engineering Calculations (Stress, Spring, Bearing, Heat Transfer etc)

Sr PROJECT ENGINEER

Confidential, Naperville, IL

Responsibilities:

• Designed off Highway Vehicle parts for Caterpillar, John Deer, & Mitsubishi using Unigraphics, Pro-Eng & SolidWorks software
• Worked directly with Manufacturing Plants/ Customers to Design Functional Fixtures and Gauges, and to solve Manufacturing issues
• Performed FEA analysis using Hymermesh Software (Linear & Non-Linear)
• Prepared detail DWGs using Unigraphics NX, Pro-Eng, SolidWorks software
• Implemented proper GD&T
• Performed Tol. Stack-ups & Classical calculations for many off vehicle parts (Front PTO for CNH combine, Mitsubishi)
• Introduced many concept designs for US Military projects (eg: Protect passengers from landmines - for light Military vehicles)
• Designed many plastic parts (Injection & Blow Molding) and Metal Alloy parts (Stamping, Die Casting, Machining & Forging)

Sr PRODUCT DESIGN ENGINEER

Confidential, Van Buren, MI

Responsibilities:

• Designed Wiper System components for Ford vehicles (Ford Escape, Mazda Tribute, Taurus, Lincoln) using PRO-Eng, I-DEAS software
• Worked in many NPI projects
• Worked directly with Manufacturing Plants and Suppliers to Introduce New Products
• Designed Hybrid & other AC Compressor (Piston, Scroll) parts using Pro-Eng software
• Designed Parts & Involved of Testing of Prototype CO2 AC Compressors
• Designed complete cost-effective AC compressor to meet customer expectation ($25/part)
• Designed cost-effective AC compressor clutch to meet customer expectation ($10/part)
• Calculated Scroll Wall Force & Counter Weights to balance (Dynamic & Static) of AC Compressors
• Designed Air Handling parts for Climate Control System using Pro-E & I-DEAS
• Performed FEA for air handling components- Cams, Doors using Hypermesh
• Proposed Gas Assist Injection Moulding/Thixo Molding to replace conventional Injection/Blow Moulding parts
• Introduced many innovative designs- a member of Innovative Design Group to solve critical design and manufacturing issues
• Performed FEA for wiper system using Hypermesh, Abacus, Nastran, and I-DEAS
• Performed Manual Calculations (Stress, welding, reverting, fatigue, load distribution etc)
• Interacted with Ford Engineers and Program Managers
• Interacted with Manufacturing Plants & UAW employees
• Performed Tolerance Stack ups and Interference calculations
• Provided technical advice to suppliers to solve Design. Manufacturing, & Process issues
• Proposed concept designs to reduce cost (saved 5 million/year) and to improve quality
• Performed DFMEA/PFMEA/Tol. Stack-ups for various products
• Prepared DWGs with proper GD&T
• Designed & Performed various validity and reliability tests
• Worked closely with cross functional teams to improve quality and reduce cost of products

DESIGN ENGINEER

Confidential, Ft. Wayne, IN

Responsibilities:

• Designed various exterior and interior body parts (Vehicle Hoods, Bumpers, Grilles, Fenders, Reinforcements, Headlights, and Mirrors etc.) for New Generation Trucks and Buses using Unigraphics
• Worked in a NPI project (2000 Medium Size Truck)
• Worked directly with Cross Functional Teams, Plants, and suppliers to Introduce New Products
• Designed cost-effective Plastic/Stamping parts
• Performed classical stress calculations, and FEA (ANSYS) for various Truck parts
• Prepared Detail, Assembly, and Installation DWGs using Unigraphics
• Implemented proper GD&T in order to reduce manufacturing cost and improve quality
• Performed Tolerance Stack ups and Interference calculations
• Presented concept designs to management to improve the product and to reduce the cost

DESIGN ENGINEER

Confidential

Responsibilities:

• Designed a complete Tag Axle drive control mechanism for highway coaches (NewFlyer Bus Industries)-patentable
• Designed Engine parts, Body Exterior, Interior parts for various Buses, and Cars (GM) from concepts to implementations using Unigraphics
• Worked directly with Manufacturing Plants/ Customers to Design Functional Fixtures and Gauges
• Designed complex Plastic & Metal Parts for many customers using UG, Catia, and SoildWorks
• Performed FEA analysis using ANSYS, & Hypermesh software
• Prepared a technical report for the Tag Axle drive mechanism to apply for patent
• Designed various Powertrain parts for hybrid buses (engine mounts, transmission mounts, air cooling system, radiator shrouds, motor control panels)
• Prepared Detail, Assembly, and Installation drawings using UG, Catia, & Solid Works
• Implemented proper GD & T in order to reduce manufacturing cost and improve quality
• Prepared design reports for various projects
• Designed fuel tanks & fuel lines in Germany using Unigraphics for GM Opal car
• Performed Tolerance Stack ups and Interference calculations
• Performed calculations to find the lifetime of linear motion systems
• Designed parts for a high-speed paper folding machine
• Selected suitable vibration isolators, bearings for bus engines and transmissions
• Communicated with customers/suppliers to select suitable standard parts

DESIGN ENGINEER

Confidential

Responsibilities:

• Designed Automotive Fuel Lines and Break Lines for GM (GMT 800) using Unigraphics
• Designed Gauges, Fixtures and Dies for Toyota, GM, Ford, and Chrysler using UG
• Designed tube bending, tube forming, leak testing machine parts using Unigraphics
• Prepared Detail, Assembly, and Installation DWGs using Unigraphics
• Responsible for building prototypes and optimizing designs to reduce the production cost
• Implemented proper GD & T to eliminate assembly difficulties
• Prepared CNC programs for 3 Axis and 5 Axis machine centres
• Performed manual Engineering calculations to optimize the design

RESEARCH ASSISTANT

Confidential

Responsibilities:

• Conducted laboratory tests for Undergraduate Students
• Tutored Computer Aided Engineering for Undergraduate students
• Designed and manufactured a Rotational Moulding machine to perform research on polymer using I-DEAS software
• Performed FEA using I-DEAS software and compared with manual stress analysis methods

DESIGN ENGINEER

Confidential

Responsibilities:

• Designed & Manufactured the first Locomotive in Sri-Lanka history- Received "The Best Design of the Country" award
• Designed locomotive parts using AutoCad
• Analysed stress distribution, tensile failures, compression failures, buckling of structure, fatigue life, heat transfer, deflection, displacement and fracture behaviour of Locomotive components
• In charge of stamping, drilling, turning, boring, planning, slotting, milling, grinding, horning, tread cutting & thread forming, and case hardening shops
• Designed and manufactured a Rubber Moulding Machine to produce oil seals and o-rings to save money- Used to export
• Performed non-destructive test for locomotive parts to find cracks and performed fracture mechanics calculations to analyse crack proportions and failures