Girish Varma Alluri

Project: Concrete Washout System, Smart Release BulkX, Upright Column Skip, Laydown Column Skip

Description: Design and development of Conquip catalogue items as per location and customer requirements.

Summary:

• Evaluating site-specific customer needs across North America, Australia, and the EU to align project planning.
• Design criteria are established according to the equipment’s specific operational site.
• The workflow includes submitting a preliminary proposal drawing, followed by a finalized sign-off drawing based on the stated requirements.
• Developing full-scale design packages: 3D modeling, manufacturing drawings, laser-cut layouts, BoMs, and technical manuals.
• Inputting part attributes and engineering data into Teamcenter, then executing the release workflow for final approval and status assignment.
• Developing internal processes and plans for mechanical verification, product development and factory processes.
• Liaising with procurement & production during every stage of development of prototype units.
• Attend production meetings on weekly basis to coordinate mechanical designs and mitigate design conflicts, and coordinate delivery timelines.
• Testing the products based on location-based regulations and standards to which its deployed.
• Providing end-to-end support for physical builds, production launches, and rigorous testing through to customer field evaluations
• Documenting and processing ECRs and MCRs to capture design-to-production feedback and maintain configuration control
• Compiling comprehensive test documentation and performance reports following the initial build phase.
• Evaluate final product's overall performance, reliability and safety.
• Conducted preventive maintenance inspections and routine service.
• Performed preventive maintenance on schedule to maintain performance of lifting attachments.

Project: Automated Coil Handling Systems (CMB)

Description: Design and development of Hydraulic Downenders, Coil Cars, Twin-Arm Turnstiles, and Precision Feeders.

Summary:

• Reviewing preliminary proposal and civil site drawings to define the technical design scope and spatial constraints.
• Managed the Development Release phase in PDM, transitioning engineering data and multi-level BoMs to the procurement department for project costing and vendor bidding.
• Collaborated with Project Managers and Lead Engineers to perform trade-off analyses for electromechanical systems, selecting between Pneumatic, Hydraulic, and Electric actuation based on power density, precision requirements
• Liaised effectively between purchasing department and automation department facility, keeping parties informed of project changes.
• Engineered mechanical frameworks with integrated provisions for automation hardware, including precision mounting for electric servos, high-pressure manifold routing for hydraulic systems, and strategic placement of industrial sensors to ensure closed-loop control.
• Utilizing 3D CAD and stackup analysis to optimize manufacturing tolerances, reducing assembly time and ensuring 'First-Time-Right' fit for bespoke packaging modules.
• Identified suitable materials for production use that aligned with environmental concerns and budget constraints.
• Developing high-fidelity weldment and sub-assembly drawings, featuring detailed exploded views and itemized balloons to streamline complex mechanical integrations.
• Deconstructing complex automated systems into manageable, high-definition sub-modules to facilitate concurrent engineering and clear requirement allocation across multidisciplinary teams.
• Coordinating comprehensive factory trial fits to validate structural alignment, component interfacing, and mechanical clearances prior to functional testing.
• Leading FAT and SAT protocols for bespoke packaging lines, ensuring 100% compliance with design specifications and regional safety standards prior to final customer handover.
• Managing the post-design lifecycle by generating detailed technical documentation and 'As-Built' Bills of Materials (BOM) to facilitate global procurement and field service support.

• Led on-site discovery workshops to capture technical requirements and user needs for upcoming projects.
• Interfaced directly with clients at their locations to translate complex business problems into actionable project roadmaps.
• Used nesting software for sheet layouts, reducing material waste by 15% through precise geometric dimensioning and CAD/CAM integration nesting software.
• Calculated precise flat pattern development drawings using neutral axis and K-factor analysis to ensure dimensional accuracy in multi-bend fabrication processes.
• Eliminated third-party fabrication costs by designing and building a proprietary rolling system, optimizing material handling and reducing lead times for curved sheet metal assemblies.
• Engineered a high-precision manufacturing prototype for Indian Railways, utilizing DFM (Design for Manufacturing) and optimized nesting strategies to meet stringent weight and structural integrity requirements for tender submission.
• Engineered and executed high-precision prototypes for Bombardier Bench Test Equipment (BTE), integrating Laser cut sheet metal components with precise bending and DFM principles to ensure structural integrity during rigorous functional testing.

Project: Truck Vehicle FUSO - Daimler

Description: Simulation using Catia V5 DMU Kinematics

Summary:

• Understanding the Customer requirements and studying the degree of freedom required for kinematics simulation.
• Developed functional assemblies using CATIA V5 DMU Kinematics, simulating mechanical motion to identify interference and clearance issues during the design phase.
• Engineered digital mock-ups (DMU) with advanced kinematic joints (Revolute, Prismatic, Cylindrical), validating the range of motion and operational envelopes of mechanical systems.
• Creating the skeleton as per the requirement, and assigning the links and mechanisms as required.
• Providing the model to CAE team for further analysis
• Developed native NX models from CATIA V5 source files, ensuring full feature-based intelligence and parametric stability.
• CADIQ to validate model integrity, achieving a maximum deviation of less than 0.05mm between source and target models.
• Applied Daimler-specific startup files and methodologies to ensure all deliverables met global Mercedes-Benz engineering standards.
• Re-created complex 2D technical drawings in NX, maintaining 1:1 parity with original CATIA specifications.

Project : Global Slat 7000/8000 Actuator Program - UTAS

Description : Creating the Casting & Machining models and drawings using UG NX 7.5, Teamcenter, GD&T & Stackup Aalysis.
Summary : Undergone a study of kinematics involved in Actuation system along with importance for actuation on an aircraft.

• Provide technical presentations including preliminary design reviews. Measure & Ensure Customer satisfaction, Quality, Cost and Delivery. Project effort estimations, setting up milestones & Deliverable for projects, Risk Analysis & Risk Mitigation for projects, Monthly Target charts.
• Worked on creation, modification, analysis and optimization of design for various Actuation
  components.
• Developed production drawings as per UTC standard drawing practices and releasing the workflow on Teamcenter for approval.
• Applied ASME Y14.5 GD&T principles to perform stackup evaluations, ensuring design intent was maintained from CAD model to final inspection.
• Designed and implemented quality control processes to facilitate customer satisfaction.
• Reviewing of models with client and doing necessary changes as required.

Project : Bus Power Control Unit (BPCU) & Over Voltage Protection Control (OPU)
Description : Design &Development of Mechanical concepts for Packaging of BPCU and OPU.
Summary :

• Design including development of enclosure which can with stand Environmental condition and EMI/EMC as per RTCA DO-160 standard & sizes as per ARINC600.
• Engineered high-density mechanical packaging for modular circuit boards, optimizing internal layouts for space efficiency, thermal management, and ease of assembly.
• Study of Electrical components behavior under Vibration and Heat dissipation.
• Creating 3D models & Production drawing as per ASME Y14.5 1994 and UTAS Standards.
• Understand the Engineering Inputs and write the requirement for documentation of Logical and repeatable jobs to increase the productivity.
• Directed the design evolution from concept to production, ensuring all customer-mandated modifications were integrated without compromising structural integrity or project timelines.
• Effort Estimations, Setting up Milestones & Deliverable and Risk Analysis & Risk Mitigation

Project: Press Tools for emerson india

Description: Design and development of press tools for blanking, deep drawing, piercing, cropping and flaring.

Summary: Design the layout of the press tool and planning the manufacturing processes.

• Create the general arrangement drawing for the press tool and check the tonnage and press availability.
• Optimized material selection for press-tool components, balancing core toughness with surface hardness to extend tool life.
• Create the 3D drawings, Part drawings and providing GD&T with surface finishes for hardened parts.
• Creating BOM on SAP system to allow parts to be issued for RFQ and sourcing accurately and robustly.
• Liaising with tooling department to best utilize the existing parts and providing data necessary to ensure timely completion of project.
• Performed trial batch and adjusting tooling required for final component parameters.
• Recording the data captured in modification of the tooling though internal MCR.
• Developed total preventative maintenance procedures for tools, dies and bending equipment, leading to 10% decrease in equipment downtime
• Lead reverse engineering initiatives to repurpose existing tooling for cost reduction.