Kaustubh Sakhare

Senior Technical Lead (E Div. VAVE)

• Responsible for ideation and implementation of VAVE topics across the different regions and locations.
• Created & managed several matched team calls to track and progress VAVE project's.
• Planned and successfully implemented digital VAVE workshops to generate cost down ideas with different suppliers in EU and GCR like Feintool, Hago, Voit, Ernst Metal,transform,FCC.
• Currently working on 8HP (Gen 2/3/4) to implement Cost down ideas.
• Responsible for collaboration with suppliers for VAVE projects
• Good knowledge and understanding of parts/layout of E Div.products.
• Trained/training different colleagues on Knowhow of different ZF E Div.products like (8HP/9HP/EVD) and overall VAVE processes.
• created supplier presentations, project time-plans, business calculations and other technical documents and MOM's for several VAVE measures.
• lead the team for inverter cost down benchmark studies (Gen-6 & STLA e-Rad)
• Delivered exceptional customer experiences by collaborating closely with different counterparts during all stages of product development life cycle, from ideation to deployment.
• currently mainly responsible for SC VAVE topics.
• learned and worked on CAE tools like permas, Hypermesh to support VAVE topics
• worked on Benchmarking and reverse engineering 8speed-GM, 8-speed Aisin, Jatco 7speed, Shengrui 8AT, Eaton 6Speed, Tata 6-Speed commercial vehicle transmission)
• worked on Tesla Y3.5, BUD,Dongfeng,Nisan,Ford and other invertars benchmarking study and created ideas.

Worked on C300-SYMC Transaxle for 2WD & 4WD, U321 transaxle for MUV Gear Designing.

• Worked on C300-FE RATIO for SYMC.
• Field failure analysis and design solution

• Responsible for VAVE of 9HP28 ZF Transmission
• Wet Clutch capacity and Piston capacity calculations.
• Benchmarking of Competitor Transmissions

• Worked as a team member of G550 Gearbox in transmission department for Tata Motors Ltd, Pune.
• Preparation of layout for complete Gearbox & its aggregate in CAD.
• Exposure in design of Gear pair, FOS, Knowledge of KISSSOFT in gear design.
• Shaft material selection, geometric layout, static & fatigue strength
• Acquaintance in design, development of cable type , direct linkage or rail system, top & bottom lever shift system
• Design development of shifter shaft detent profile, shifter fork material & geometry,Interlocks, detent block, guide plate & shift system operating
• Preparation of component, machining and assembly. Drawings and ensure timely execution
• Product designer Manual transmissions of Commercial Vehicles ultra trucks and buses
• Conducting global benchmarking session & VAVE/ICR proposals (transmission features, material,manufacturing etc.)
• Preparation and participation for DFMEA, DFS, DFM, and DFA.
• Field failure analysis
• Co-ordination between various cross functional teams like ODT , IDT, Process design, CAE, GSQA,Assembly, Special Processes, aggregate validation

Projects

• Laser welding of synchro cones on gears=> Ultra Synchronizer system MANUAL ,G550 5 & 6 speed VAVE,Design & development
• Elimination of sensing wheel by putting slots on coupling flange
• Integral housing design

• 3D Modelling and Manufacturing drawings creation using Pro/E Creo 2.0.
• Preparation and release of design BOM (Bill of Material).
• Developing castings, Fabrication components & designs from conceptual inputs.
• Quality check of completed work.
• Coordinated technical requirements, scheduling and solution development for engineering design and test issues.
• Studying & discussing a design projects with the team & determining the detail specifications of the model.
• Implementation of engineering changes and originated design change requests.