SUMMARY:

• Thirteen years of experience in Design,Development,Release,Quality,Manufacturing and Validation in Automatic transmission, Hybrid transmission, Axle, Propeller shaft, Half shaft, CVJ, Transfer case, PTU, Chassis parts.
• Worked on different components of semi Float and Full Float axle of different constructions like Banjo, Salisbury and Independent Axles design. Different Layout: FWD, RWD, AWD, 2WD,4WD and e - 4WD.
• Experience in design and development of Subsystems of Pumps and Filter, Shafts, Planetary Gear System, Torque Converter, Bearing, Housings, Differential system, Retainer Ring, final drives, Axle, transmission layout architecture and Powertrain Integration.
• Experience in working with development of hybrid transmission and PHEV and Chassis Parts development of PureEV and Integration.
• Three plus years of experience in design development of Chassis parts (knuckle, Hub Bearing, spindle, hubcap and member links) and Packaging study of chassis parts.
• Experience in Automatic transmission and axle (Bench tests, pressure test, hydraulic pulsation test, leakage, Endurance and durability testing).
• Experience in BoD/BoM, DFMEA, Supplier Validation,DVP&R,ECN, VA/VE

TECHNICAL SKILLS:

• Unigraphics NX 9 (7+ years hands on Experience)
• CATIA VR 19 (3+ years hands on Experience)
• Ideas modelling and CAE Analysis using Hyper mesh and IDEAS CAE.
• Expertise in using CAD tools, UGS's PLM and PDM tools including Team centre, VisMockup Professional
• MS Office and Minitab

PROFESSIONAL EXPERIENCE:

Confidential, Troy, MI

Project Engineer

Responsibilities:

• Quality analysis of Drivetrain Parts F150 4X4 Hub actuator and Axle whine Noise.
• Warranty spends reduction of Drivetrain Parts and Improve failure modes.
• Failure mode analysis of Drivetrain Parts Transmission Pumps and filter, Half shafts, Differential of Different carlines both Low and High mileage Warranty claims.
• Discussion with Cross functional team, Metallurgy, testing, metrology, PVT and Supplier for warranty spend reduction and Root cause analysis of Warranty returned Parts.
• Failure modes and root cause Analysis of both High and Low mileage drivetrain Parts doing teardown and writing different bench tests..
• Coordinating with Supplier for 8D and Other Test results.
• Value stream Mapping and cost analysis of Parts.
• Identify, Investigate and Address Current Model Warranty Issues including tear down of warranty returns, supplier containment and ICA/PCA
• NVH analysis of different Drivetrain Parts to study Failure modes.
• Dynamic Seal testing of Half shaft with Transmission Parts, to study oil leakage and other Failure Modes.
• Bench and Vehicle level tests of Half shaft and Transmission Pumps.
• Failure Mode analysis Problem solving done Six sigma Methodology of Transmission and Half shaft sealing system, Boot leakage, Bearing Failures and Noise concerns.

Senior Technical lead

Responsibilities:

• Light weight Design and development of Front and Rear Differential design and development of MRA2 and MSA Platforms.
• Differential analysis and optimize tradeoffs between system weight, NVH, Package, efficiency and cost.
• Design, Development, CAD/CAE loop and Validation of Structural and rotating parts.
• Identify the root cause and close development testing issues and Understand and deliver system NVH analysis - work with internal teams to assess and improve transmission and driveline performance.
• NVH analysis of Ring gear and Pinion interface and Selection of washer in Differential and side Gear by studying contact pattern analysis.
• Development of carrier Housing and Differential with Periodic review with customer and Supplier.
• Front and Rear axle development, CVJ and driveshaft DV&PR preparation and testing on vehicle/ bench level.
• Rear axle oil quantity optimization based on Frictional HP & Pattern analysis of oil migration and centre section starvation at extreme cornering loads.
• Development and testing for MLD (mechanical locking differential) for off-road applications.
• E-disconnect locking mechanism development and testing for Next Gen Vehicles.
• ITM (Intelligent torque management) and RDU calibration and testing for AWD systems.
• Resolving all issues coming from Development and Protovehicle assembly in Plant and supplier.
• Design verification and Validation plan in house team and supplier.
• Meet supplier development schedule with vehicle master plan.

Assistant Manager

Responsibilities:

• Management of parts Design Development and Analysis Of Axle components (knuckle, Hub, Suspension, Member links and bearing) of In wheel Motor Vehicle.
• Design study from scratch and analysis with help of design tool and calculation of In wheel Electric Vehicle.
• Tightening and strength Calculation of Knuckle and hub bearing.
• Brake hose routing and packaging study of chassis parts.
• Design verification Plan (DVP) and testing methodologies/ procedures on Vehicle/ Bench level of Hub bearing of In wheel Motor Pure EV.
• Life establishment of Hub bearing, Knuckle and Spindle by system performance and durability tests.
• Field failure analysis for existing systems(FMEA) of
• Digital lot Preparation and layout confirmation with other team (Brakes, suspension, Steering, wheels and tires & BIW)
• Resolve all issues coming from Proto vehicle from Plant.
• Technical reviews with all potential supplier and solve technical queries.
• Taken localization and Cost reduction of old running and new projects.
• Involved in 3-3-3 activities to reduce cost of existing Project.
• Packaging Study of Chassis Parts Of A,B and C segments Vehicles.
• Benchmarking and teardown analysis of chassis parts.
• Manage complete part development cycle, start from RFQ to adoption cycle.
• Analysis of field failures after SOP and decide counter measures for corrective actions.
• Liaison with other designers/ suppliers / purchase dept. / manufacturing dept.
• APQP documentation (FMEA, PAP, DVP&R, D&D Planning) and PAP activities.

Senior Design Engineer

Responsibilities:

• Automatic and Hybrid Transmission components & assembly design as per functional & other BOD requirements.
• Validate design based on extensive use of Tolerance stack-up analysis for various Automatic transmission subsystems & interface. Continuous Periodic review with process partner.
• VA/VE study through design, Packaging and Tolerance stack-up analysis of internal and External Components.
• Packaging Study for Automatic transmission subsystems and System Integration.
• Involved in Design, Improvement and Release activity of Pumps and Filter, transfer Shaft, Transfer Gears, Differential and Final Axle of Hybrid Transmission.
• Generating requirement Documents for the project, estimation, allocating and monitoring works to Suppliers, Trainee Engineers and Self.
• Work with component engineers and supplier to develop Internal Parts, sizing and design.
• Overall Transmission packaging, Optimization and Integration with Driveline systems.
• Packaging study of Front compartment parts and vehicle integration
• APQP documentation (FMEA, PAP, DVP&R, D&D Planning) and PAP activities.

Design Engineer

Responsibilities:

• Design, Development and Tolerance stack up creation for Axle Parts of GMT900 and 800 Pickup trucks 8.5 inch, 9.5inch,10.5 inch axles.
• Concept design and development and testing of Salisbury Axle to Banjo conversion of Tata ACE 1 Ton.
• Development of 8.6 inch Differential from scratch.
• Design and Development of Aluminum 2 Piece and 3 Piece Prop shaft for GMT 900.
• CAD/CAE loop for Axle parts.
• Detailed design of Rear Axle and Front Axle parts of Disconnect Mechanism.
• Design and Development of Universal Joint and CVJ.
• Cost reduction and weight optimization of existing and new products.
• Benchmark and teardown of competitor Axles.