Jan 2019 – Apr 2020 · 1 yr 3 mos

• Developing acquired IP from HEC UK into a product. System architecture of a disruptive low-cost two-wheeler fuel injection technology.
• Learning of independently consulting for design, fabrication, and delivery with documentation, of a turnkey prototype through iterative development. Training on DFAM from MIT APT, and application with the two major metal AM suppliers in Bangalore. Experienced the why of challenges of R&D in India after exposure to same in Germany.
• The prototype met the emission and performance requirements in dyno and field testing. Running test vehicles were demoed to top leadership of 2W division in Bosch and leading Indian OEM. Successful graduation of project towards gated Innovation phases, project acquired the customer support for series development funding.

Jan 2018 – Dec 2018 · 11 mos

• Mechanical design and development of Two-Wheeler EV and Hybrid systems in a Corporate internal Startup with Indian 2W OEM's for launches of TVS iQube and a small role in Bajaj eChetak. Hands on immersion with designing, fabricating, assembling, and mounting of iterative prototype subsystems on test vehicles. Vendor development. Design consultant to motor development team at Bosch China and vehicle integration team at OEM. Preparing series-ready drawings with design for homologation, manufacturability, feasibility, assembly, maintenance, and cost.
• Running proto vehicles successfully demonstrated to topmost leadership of Bosch and OEM customer.

Jul 2017 – Dec 2017 · 5 mos

• During bubble assignment, the Bosch SG Division spun off as SEG Automotive of ZMJ PRC.
• Redesigned a field failure component having more than one material and multiple performance requirements in a tight packaging space. Used Bosch TRIZ, generated multiple concepts, Zwicky evaluation, Rapid prototyped samples in advanced materials for testing. Coordinated with Corporate Research for material performance limits and gave input for design for manufacturability.

Apr 2016 – Jun 2017 · 1 yr 2 mos

• Concept generation, design, and AM fabrication for pre-development test prototypes and fixtures. Copper to Aluminum winding transition exploration for design and production, as supporting role.
• Independently consulted for Negative Thermal Coefficient voltage drop protection test prototypes for test bench and test vehicle. Exposure to parametric CAD for automated iterative geometry, for Multi-objective-optimization simulation, on Boost Recuperation Machine.
• First opportunity to witness the rigor and technical prowess behind German engineering at work, and of intercultural immersion. Enjoyed a trustful, free thinking and resourceful work environment.

Jan 2015 – Mar 2016 · 1 yr 2 mos

• Design and development for launch of the most compact Bosch starter platform C60, and application development for customers Ford, Hyundai, Greaves and TVS. Engineering change management activity with Hildesheim platform team. Concurrent engineering with Bosch Latin America team for C70. Developing features according to special customer requirements and challenging supplier capacities. Coordination with testing, quality, PQA and also self assembling samples in proto shop for shipping to Japanese customer.

Aug 2013 – Dec 2014 · 1 yr 4 mos

• Implemented design changes in alternator components and assembly for BMW and Daimler. Creation of 3D models, drawing and assemblies. Part list creation and Bill of Material (BOM) preparation for all associated parts. Prepared Offer model and Drawings for different OEM. Prepared casting and machining drawings for Al PDC components as per requirements specified by customer. Simplification of alternator components and coordination for CFD, Structural and Magnetic noise analysis.
• Successfully designed a dual-purpose alternator of output 240V AC🗲DC 12V for Mini Trucks with salient-pole rotor【=】to package winding turns and wire diameter. Bench-marked similar output e-machine. Prepared and coordinated for CFD simulation. Reverse engineering and hand constructing 1:1 scale model for product packaging in Mahindra.
• Test vehicle driven from Naganathpura Plant to Koramangala office without catching fire.

Jun 2009 – Jul 2009 · 1 mo · Panki Thermal Power Plant, Kanpur

• Material handling study in Coal Handling Department. Overview of plant layout and process flow.

Jun 2008 – Jul 2008 · 1 mo · Panki Industrial Estate, Kanpur

• Summer Training in the CNC Machine Shop and the Assembly Shop for the manufacturing of Circular Winding Machines. Project included preparing a Man-Machine Chart and subsequent Analysis of Value Added Time of the working duration of the Vertical Milling Centres.