UG NX
AFZALHUSAIN MADAKI
TOOL DESIGN ENGINEER
Hubli
Summary
Innovative Tool Design Engineer with expertise in CAD software and process improvement. Proven track record of enhancing production efficiency and quality through effective tooling solutions and cross-functional leadership.
Overview
7
7
years of professional experience
Work History
Tool Design Engineer, Tool Engineer
Fine Blanking Pvt. Ltd.
09.2018 - 09.2025
- Designed and developed precision tooling solutions, enhancing production efficiency and quality.
- Led cross-functional teams in tool design projects, ensuring alignment with engineering standards.
- Utilized CAD software to create detailed tool designs, resulting in reduced lead times and costs.
- Conducted thorough evaluations of tooling processes, implementing improvements that streamlined operations.
- Collaborated with manufacturing teams to troubleshoot tooling issues, minimizing downtime and enhancing productivity.
- Mentored junior engineers on best practices in tool design, fostering a culture of continuous improvement.
- Analyzed tooling performance metrics to identify areas for enhancement, driving operational excellence.
- Implemented safety protocols in tool design processes, ensuring compliance with industry regulations.
- Identified opportunities for cost reduction by analyzing material usage patterns and recommending alternative options when feasible.
- Applied problem-solving skills to troubleshoot complex issues related to tool design, ensuring timely resolution and minimal downtime.
- Provided critical support during production ramp-up phases, addressing any unforeseen challenges related to tool design or function effectively.
- Developed comprehensive technical documentation for each tool design project, providing a valuable resource for future reference.
- Maximized equipment lifespan through diligent maintenance planning and implementation of preventative measures based on detailed analysis of wear patterns on tools.
- Improved overall company reputation by consistently delivering reliable, durable, and effective tools within strict deadlines.
- Established effective communication channels with vendors and suppliers, ensuring timely delivery of necessary materials for ongoing projects without compromising quality or budget constraints.
- Contributed to increased revenue by creating custom tool designs for high-profile clients, resulting in repeat business.
- Spearheaded tool design standardization efforts, resulting in more easily interchangeable components and reduced production downtime.
- Reduced manufacturing costs through strategic optimization of tool designs for improved efficiency and production rates.
- Achieved substantial time savings by automating repetitive tasks in the design process using advanced software applications.
- Successfully completed numerous high-stakes projects under tight deadlines by employing exceptional time-management skills and a keen attention to detail throughout the design process.
- Pioneered groundbreaking solutions to complex problems with creative approaches in materials selection, fabrication techniques, or assembly methods applied in new or modified tool designs.
- Enhanced tool performance by designing and implementing innovative concepts in collaboration with the engineering team.
- Streamlined workflow processes, resulting in shorter lead times and quicker project completion by optimizing tool design layouts.
- Applied mechanical problem solving skills to develop creative solutions for quality products.
- Tested newly installed systems, closely monitoring functionality and adherence to operating specifications.
- Interpreted blueprints, technical drawings, schematics and computer-generated reports for new product development.
- Drafted assemblies, models, and other technical drawings.
- Designed budgets and cost estimates for projects with speed and accuracy while working closely with clients, drafters and employees to determine best courses of action.
- Performed pre-construction, quality and safety management, as well as constructability review, start-up and commissioning.
- Effectively developed models, assemblies and drawings using Autocad and [UG NX].
- Educated clients on more energy-efficient solutions for old systems that meet project requirements for timelines and budgets.
- Created detailed technical documentation for tooling designs, ensuring compliance with industry standards and best practices.
- Conducted thorough analysis of existing tools and processes to identify areas for optimization and improvement.
- Managed multiple tooling projects simultaneously, delivering high-quality results while adhering to strict timelines.
- Mentored junior engineers in tool design principles and techniques, fostering a culture of continuous learning.
- Participated in the development of training programs for staff on new tooling technologies and methodologies.
- Trained junior engineers in best practices for tool design, maintenance, and troubleshooting techniques.
- Implemented preventative maintenance programs to extend the life of critical tools and reduce repair costs.
- Improved overall equipment effectiveness with thorough analysis of tool performance data.
- Developed cost-effective solutions for tooling issues, resulting in significant savings for the company.
- Collaborated with the manufacturing team to optimize tool designs for increased efficiency and productivity.
- Evaluated new technologies for potential application in existing operations, increasing productivity through process innovation.
- Standardized procedures across multiple locations, facilitating consistency in tool usage and maintenance practices throughout the organization.
- Resolved equipment failures promptly by conducting comprehensive investigations into possible causes and implementing appropriate countermeasures.
- Identified suitable materials for production use that aligned with environmental concerns and budget constraints.
- Developed internal processes and plans for mechanical verification, product development and factory processes.
Education
Tool And Die Making - Machanical
Govt Tool Room And Training Center(GTTC)
Hubli, India 04.2001 -
Skills
Tool design
CAD software
Precision tooling
Cross-functional leadership
Process improvement
Technical documentation
Cost reduction
Preventative maintenance
Tooling performance analysis
Manufacturing collaboration
Mentorship and training
Project management
Material selection
Problem resolution
Assembly modeling
Client communication
Innovation in design
Effective communication
3D modeling expertise
Continuous improvement mindset
Mechanical engineering principles
Quality control standards
Manufacturing processes
Geometric dimensioning and tolerancing
Failure mode analysis
Lean manufacturing techniques
Engineering drawings interpretation
Computer-aided engineering
Finite element analysis
Tooling maintenance strategies
Design verification planning
Sheet metal design
Machine tool operation
Cost estimation experience
Statistical process control
Customer requirements analysis
Machine operation
Supplier management
Tooling design
Design for manufacturability
Hydraulic systems
Welding techniques
Pneumatic systems
Fixture design
Teamwork
Teamwork and collaboration
Problem-solving
Time management
Attention to detail
Problem-solving abilities
Multitasking
Multitasking Abilities
Reliability
Excellent communication
Critical thinking
Organizational skills
Team collaboration
Active listening
Adaptability and flexibility
Verbal and written communication
Decision-making
Team building
Relationship building
Self motivation
Mechanical designs
Analytical thinking
Goal setting
Materials planning
Professionalism
Complex Problem-solving
Employee management
Mechanical drawing
AutoCAD
Preventive Maintenance
Time management abilities
Continuous improvement
Written communication
Quality assurance
Mechanical measurements
Product testing
Additional Information
VISITED HONDA COMPANY AT HARIYANA GURGAON
TWO WHEELER MANUFACTURING PLANT FOR TOOL INSTALLATION AND WORKED AS A TRAINER FOR COMPANY EMPLOYEES ( 3 MONTHS).
Software
AUTOCAD
Interests
Product and Tool Designing
Fixtures and Gauges Design
3D Modeling and similation
Timeline
Tool Design Engineer, Tool Engineer
Fine Blanking Pvt. Ltd.
09.2018 - 09.2025
Tool And Die Making - Machanical
Govt Tool Room And Training Center(GTTC)
04.2001 -
PLAYING CRICKET
All rounder