SUMMARY:

• Over Ten years of industrial experience in Design, Development and Release of Automotive components.
• Strong Experience at Ford Programs in design of Body interior Plastic Injection Molded Components.
• Strong experience in design and development of Sheet Metal Components.
• Skilled in teh design of high quality plastic injection molds wif mechanical and hydraulic actions, including; cam, angle pin, and hydraulic slides, stripper and floating plates, lifters, wedges and two - stage ejection.
• Strong experience in Quality, Testing and Lean Manufacturing in Automotive systems.
• Strong experience in CAD tools like CATIA V5 R17, PRO-E and SDRC IDEAS.
• Strong experience in Team Center Engineering, TDM and Metaphase.
• Strong experience in GLOBAL 8D, SIX SIGMA, DFMEA, DVPR, EFDVS, PPAP, PESR, AVBOM, APQP.
• Knowledge in design and development of Exterior body components.
• Knowledge in manufacturing of plastic molds, press tools, Jigs and fixtures.
• Expert management skills in leading a team to achieve excellence.
• Good noledge in Plastic molding processes like vacuum forming, Thermoforming and Blow molding.
• Good noledge in CNC Programming and Operations.

PROFESSIONAL EXPERIENCE:

Lead Engineer

Confidential

Responsibilities:

• Design, Development and Release of Instrument Panel for both Mack and Volvo meeting QDCF Requirements.
• Design, Development and Release of Door Panel for both P6605 (Volvo) and P7605 (Mack) Programs.
• Working as ETL accountable for QDCF of Door Panels.
• Maintenance of IP, Seats, HVAC, Door Panel in teh Driving module for both Volvo and Mack.
• ETL Role in CAB Blue Light Program, quickly resolving factory protuses coordinating wif employees in Brazil, India and vendors meeting Volvo technical requirements.

Lead Engineer

Confidential

Responsibilities:

• Designed and released Body Interior Components like Instrument Panel, Centre console, side trim, and HVAC system for NMEVA, first electric truck in USA, a premier most project of NAVISTAR.
• Responsible for teh complete Product design from meeting Engineering challenges and developing concepts to finished drawings and bill of materials for Body interior components for NMEVA, first electric truck in USA.
• Designed, developed and released teh Product Graphics and Badges for NMEVA electric truck.
• Did Ergonomics study on teh A, B and C visibility zones for windshield and Side glass to package 360 watts /13.8 V wiggled wire to defog/defrost for forward vision for NMEVA electric Truck.
• Did cost analysis in concept stage to capture all risks in terms of carry over and new products estimating and modeling for NMEVA electric truck.
• Designed a rotary two-shot mold for door to hood seal incorporating molecular bond technology to resolve wind noise issue.
• Designed, developed and validated REPTO Feature access panel, ALTEC 102 pin connector package in CAB interior, and new Hood seal for LONE STAR meeting all FMVSS and Navistar System Design specifications.
• Worked closely wif quality control to develop flow diagrams, process failure mode and effects analysis, and control plans for Q-9000 .

Senior Design Engineer

Confidential

Responsibilities:

• Designed and released Floor Console, Instrument Panel inside teh 2010 Fisker Karma Plug in Hybrid car. Designed HVAC climate Control plastic injection molded components like A/C Panel Duct, Demister Duct, Heater Duct and HVAC air Inlet in teh IP area.
• Perform feasibility studies on new part designs for improved mold ability.
• Conducted CFD analysis for teh air flow thru teh ducts all inside teh car for optimum Passenger comfort as per teh customer requirements. Packaged and released mechanical and electronic components like speaker, radio, navigator in teh instrument Panel. Done feasibility study on attachment strategy for various sheet metal and plastic components like sills, package tray, side view mirrors etc.

Lead Product Engineer

Confidential

Responsibilities:

• Designed and released various plastic injection molded components for Floor Console, center finish panel, Instrument Cluster bezel, Register Bezels, Adapter Ducts, glove box, Speaker, radio etc. meeting all requirements of plastic injection molding for Ford fusion CD 338 and Lincoln MKZ CD 378 where IP is manufactured by skin and foam method (soft IP).
• Trained, developed and assigned work to different teams of engineering. Were able to plan and meet project and test schedule as per Ford milestones. Executed more specialized mechanical and electrical tests on product components or series of components in various ford programs and was able to multitask by handling diverse assignments concurrently.
• Engineered evaluation of all 2D and 3D cad (as per teh FC milestones) to develop a final approved surface in a Concurrent engineering approach engaging Ford Design studio, suppliers and tool designers.
• Conducted feasibility assessment of clay model right from teh beginning by establishing hard points for . Develop B-side features after packaging all internal components and modules wifin teh specified tolerance (by bringing ergo zone, foot zone, Knee zone etc.).
• Conducted stack up study (DVA). Managed CAE work on 3dCAD in teh feasibility stage. Drove suppliers to choose right materials as per color harmony and functionality wif sufficient benchmarking and research. Also assured all interfaces are designed wif proper locating and attachment strategy to have an edge in teh competition by achieving tight tolerance for improved appearance.
• Completed necessary documents required for ok to tool process like DFMEA, DVPR, BOUNDARY DIAGRAM, P DIAGRAM, RCL, EFDVS, AVBOM, PESR, quality history (TGW’S, R/100), SA, ESOW AND ED&T.

Senior Product Design Engineer

Confidential

Responsibilities:

• Actively involved in teh feasibility assessment and design activities of J61J 2008 Mazda 6. Supported teh onsite project in teh Mazda Design & Development center in Hiroshima, Japan in teh year 2005.
• Designed and developed Headliners, Interior Hard Trim plastic injection molded components ( A pillar, B pillar, Scuff plates and cowls) and IP components (meter cover, steering column, center finish panel, Floor Console, glove box IP substrate) incorporating latest design criteria from Mazda, Japan meeting all SDS and FMVSS requirements.
• Developed design criteria sections for attachment scheme and sheet metal locations for B-side panel features and conducted vision study in teh design feasibility stage for J61J program by PRO-E.
• Prepared and maintained design related documents to support program - DFMEA, design statement of work (SOW’s), design verification plan & report (DVP&R), bill of material (BOM).
• Did Troubleshooting of sink marks, warp, Weld lines, short shot and gas traps for different plastic parts.

Design Engineer

Confidential

Responsibilities:

• Lead feasibility assessment and release of new instrument panels.
• Packaged various plastic injection molded components using SDRC IDEAS and PRO-Engineer like steering column upper and lower, center finish panel upper and lower, glove box upper and lower, floor console rear panel, armrest, speakers, subwoofer, amplifiers, antenna, etc., throughout teh I/P and Console.
• Developed B-side panel features wif active participation right from design feasibility to release for various FORD programs like D219/D258, U204, U377, and P221 and registers for Toyota Sienna using CATIAV5 and PRO-E.
• Designed and released components of IP and Console for Nissan ZW truck as well as QW 2row and 3 row series for year 2007 (includes new proposals developing 2d sections, conducting load study using kinematics).