Kanhu Charan Sahu
Summary
Engineering professional with 13 years of experience in automotive plastic components, combining strong leadership in NPD with deep CAE expertise.leading cross-functional teams to deliver innovative, reliable, and cost-effective solutions, while continuously driving process improvements and organizational growth
Vast experience in Plastic &Rubber injection Moulds in field of Automotive Industry CAE Analyst , New Product Development
Overview
13
13
years of professional experience
Work History
Sr Project Technical Engineer
Valeo India Pvt Ltd
07.2021 - Current
CAE Analyst (Engineer)
DEP IND PVT LTD
09.2019 - 06.2021
- Experienced in managing and executing multi-domain CAE projects for automotive plastic components.
- Acted as SPOC for simulation activities, providing Moldflow simulation support and addressing day-to-day CAE requests from customers.
- Performed complete simulation sequences - Cooling + Fill + Pack + Warp + Core shift analysis - to deliver optimized solutions.
- Recommended design and process solutions for injection molding issues, ensuring robust manufacturability.
- Skilled in simulation of mono & multi-color molding (2K & 3K), over-molding, insert molding, IML and rubber insert molding processes.
- Conducted troubleshooting of molding defects (warpage, weld lines, shrinkage, short shots, etc.) through Moldflow analysis and proposed design/process modifications.
- Optimized feed system, cooling channel design, and process parameters for injection molded and over-molded parts.
- Correlated simulation results with trial (GENBA) results, ensuring reliable predictive accuracy.
- Facilitated parameter transfer from simulation to shop floor and vice versa, improving process reliability.
- Delivered comprehensive engineering reports, presentations, and technical documentation to stakeholders.
- Developed new design rules, process standards, and best practices to enhance CAE methodologies.
- Collaborated with cross-functional teams (Design, Tooling, Manufacturing) to achieve robust part design and functionality.
- Deputed at FORD Motors
Jr Project Engineer
MAHLE FILTER SYSTEM IND LTD
03.2013 - 09.2019
- Led end-to-end new project development for automotive plastic components from project kick-off to SOP
- Conducted feasibility studies (design, manufacturability, tooling, and process feasibility) to ensure successful project execution
- Prepared and reviewed cost estimations for new components, balancing customer requirements and profitability.
- Managed supplier selection process, including RFQ evaluation, capability assessment, and sourcing finalization
- Coordinated design reviews, DFM/DFA analysis, and mold flow simulations to optimize product quality and manufacturability.
- Oversaw tooling and part trials (T0 to SOP), ensuring adherence to quality standards and project timelines
- Drove process validation, PPAP, and APQP activities in alignment with customer and OEM requirements
- Collaborated with cross-functional teams (Design, Quality, Purchase, Production) for seamless project execution
- Handled change management (ECR/ECN) and ensured timely implementation in ongoing projects
- Ensured compliance with automotive standards (IATF 16949, customer-specific requirements, safety standards)
- Acted as a technical mentor for junior engineers, fostering knowledge sharing in tooling, simulation, and NPD processes
Education
Diploma - Mechanical engg
SCTE&VT
Post Diploma - Tool Design & Manufacturing(PDTDM) CAD/CAM
Central Tool Room & Training Center
BhubaneswarB-TECH - Mechanical Engineering
Skills
- AUTODESK MOLDFLOW
- MOLDEX
- ANSYS WORKBENCH
- AUTODESK POWER SHAPE
- CATIA
- Altair SIMLAB
Software Skills
AUTODESK MOLDFLOW, MOLDEX, ANSYS WORKBENCH, AUTODESK POWER SHAPE, CATIA, Altair SIMLAB
Languages
- Oriya
- Hindi
- Tamil
- English
Projects
Engine Crank Cover, Intake manifold, Hard Trim, Console, Door Trim, IP, Head lamp, Rear lamp, India, North America, Asia Pacific, South Africa, China, Europe
Disclaimer
I hereby declare that the information furnished above is true to the best of my knowledge.
Roles And Responsibilities
Led end-to-end new project development for automotive plastic components from project kick-off to SOP, Conducted feasibility studies (design, manufacturability, tooling, and process feasibility) to ensure successful project execution, Prepared and reviewed cost estimations for new components, balancing customer requirements and profitability., Managed supplier selection process, including RFQ evaluation, capability assessment, and sourcing finalization, Coordinated design reviews, DFM/DFA analysis, and mold flow simulations to optimize product quality and manufacturability., Oversaw tooling and part trials (T0 to SOP), ensuring adherence to quality standards and project timelines, Drove process validation, PPAP, and APQP activities in alignment with customer and OEM requirements, Collaborated with cross-functional teams (Design, Quality, Purchase, Production) for seamless project execution, Handled change management (ECR/ECN) and ensured timely implementation in ongoing projects, Ensured compliance with automotive standards (IATF 16949, customer-specific requirements, safety standards), Acted as a technical mentor for junior engineers, fostering knowledge sharing in tooling, simulation, and NPD processes, Experienced in managing and executing multi-domain CAE projects for automotive plastic components., Acted as SPOC for simulation activities, providing Moldflow simulation support and addressing day-to-day CAE requests from customers., Performed complete simulation sequences - Cooling + Fill + Pack + Warp + Core shift analysis - to deliver optimized solutions., Recommended design and process solutions for injection molding issues, ensuring robust manufacturability., Skilled in simulation of mono & multi-color molding (2K & 3K), over-molding, insert molding, IML and rubber insert molding processes., Conducted troubleshooting of molding defects (warpage, weld lines, shrinkage, short shots, etc.) through Moldflow analysis and proposed design/process modifications., Optimized feed system, cooling channel design, and process parameters for injection molded and over-molded parts., Correlated simulation results with trial (GENBA) results, ensuring reliable predictive accuracy., Facilitated parameter transfer from simulation to shop floor and vice versa, improving process reliability., Delivered comprehensive engineering reports, presentations, and technical documentation to stakeholders., Developed new design rules, process standards, and best practices to enhance CAE methodologies., Collaborated with cross-functional teams (Design, Tooling, Manufacturing) to achieve robust part design and functionality.
Personal Information
- Available: 60 days
- Date of Birth: 04/20/91
- Gender: Male
Timeline
Sr Project Technical Engineer
Valeo India Pvt Ltd
07.2021 - Current
CAE Analyst (Engineer)
DEP IND PVT LTD
09.2019 - 06.2021
Jr Project Engineer
MAHLE FILTER SYSTEM IND LTD
03.2013 - 09.2019
Diploma - Mechanical engg
SCTE&VT
Post Diploma - Tool Design & Manufacturing(PDTDM) CAD/CAM
Central Tool Room & Training Center