Koustubh Avinash Gondkar
Pune
Summary
Senior Design Engineer with 4+ years of experience in mechanical design and industrial automation. Expert in designing automated production stations, conveyor systems, and laser cutting machines for automotive and EV manufacturing. Proficient in 3D CAD (SolidWorks, Solid Edge, Inventor) and PLM systems (Clarity ERP, Teamcenter). Skilled in new product development (NPD), design for manufacturability (DfM/DfX), lean manufacturing, and cross-functional collaboration to deliver cost-effective, high-performance, and reliable automated solutions at Wipro-PARI and Suresh Indu Lasers.
Overview
7
7
years of professional experience
1
1
Certification
Work History
Senior Design Engineer
Wipro-PARI Pvt Ltd (Shivamtech Engineering)
06.2023 - Current
- Designed and developed automated and semi-automated production stations for automotive and EV manufacturing lines serving global OEMs
- Designed manual and automated battery packing assembly stations for global OEM – Tesla Inc. (USA)
- Engineered OSHA-compliant staircases, access platforms, and maintenance structures for automation equipment
- Designed and engineered automated engine assembly and inspection stations featuring cylinder head bolt tightening and precision axial play inspection stations for crankshaft and thrust washer presence, for global OEM – Volvo Eicher Commercial Vehicles
- Designed and supported tray line assembly systems for global OEM – Ford, including station layouts and material flow optimization
- Applied Design for Manufacturing, Assembly, and Cost (DfMA / DfX) methodologies to improve efficiency and reduce system cost
- Conducted DFMEA to evaluate design risks, material selection, and long-term reliability of automated stations
- Developed ducting and routing systems for electrical wiring, pneumatic circuits, and flexible piping
- Created GA layouts, assembly drawings, fabrication drawings, and BOMs to support manufacturing and site installation
- Managed CAD data, revisions, and technical documentation using Clarity ERP
- Worked closely with electrical, PLC, application, and manufacturing teams to ensure seamless system integration
R&D Design Engineer
Suresh Indu Lasers (SIL Pvt Ltd)
01.2022 - 06.2023
- Led concept development and machine design for fiber laser cutting machines, converting customer requirements into scalable automation-ready solutions considering machine footprint, portability, ergonomics, and HMI/user interface
- Managed Product Lifecycle Management (PLM) activities using Teamcenter 12.0, including Engineering Change Orders (ECOs), BOM control, and revision management
- Designed machine enclosures, guarding, and covers to improve operator safety, aesthetics, thermal management, and operational efficiency
- Selected and validated critical motion control components such as bearings, linear guides, LM rails, LM blocks, and transmission elements based on load calculations, life analysis, and precision requirements
- Designed and integrated automation conveyors and material handling systems including slat conveyors, hinged belt conveyors, flat belt conveyors, and skid roller conveyors
- Coordinated with electrical automation, PLC, controls, application, and assembly teams to ensure seamless machine automation integration and manufacturability
- Projects Executed
- Fiber Laser Cutting Machine (FLC 6525)
- Fiber Laser Cutting Machine (FLC 4025)
- Slat & Hinged Belt Conveyor Systems
- Flat Belt Conveyors & Skid Roller Systems
Internship Trainee
GMT Industry
02.2021 - 04.2021
- Conducted a comprehensive case study on housing rocker lever manufacturing
- Identified and analyzed seven wastes (TIMWOOD) targeted by lean manufacturing
- Implemented Single Minute Exchange of Die (SMED) techniques to reduce mold changing time
- Documented process improvements and their impact on production efficiency
Trainee
Greaves Cotton
06.2018
- Studied engine assembly processes and quality control measures
- Assisted in various stages of engine assembly under supervision
- Documented assembly procedures for training purposes
- Gained practical understanding of manufacturing operations
- Participated in standard operating procedure development
Trainee
Sky Industries Tilawani
01.2019 - 05.2019
- Assisted supervisors in inspecting various components using precision measuring instruments
- Contributed to quality control procedures and documentation
- Analyzed measurement data for specification compliance
Education
Bachelor of Technology (B.Tech) - Mechanical Engineering
Kolhapur Institute of Technology's Institute of Management Education and Research
Kolhapur01-2021
Skills
Autodesk Inventor
SolidWorks
SolidEdge
AutoCAD
Concept Design
NPD
Reverse Engineering
Layout
DFM/DFA
Lean Manufacturing
Value Engineering
Material Selection
Time Management and Prioritization
Problem Solving and Decision Making
Microsoft Office Suite (Word
Excel
PowerPoint
Outlook)
Certification
- Course On SolidWorks Essentials
- Internship Completion Letter
- Inplant Training
- Completion Of Basic Training
- Membership Certificate
Timeline
Senior Design Engineer
Wipro-PARI Pvt Ltd (Shivamtech Engineering)
06.2023 - Current
R&D Design Engineer
Suresh Indu Lasers (SIL Pvt Ltd)
01.2022 - 06.2023
Internship Trainee
GMT Industry
02.2021 - 04.2021
Trainee
Sky Industries Tilawani
01.2019 - 05.2019
Trainee
Greaves Cotton
06.2018
Bachelor of Technology (B.Tech) - Mechanical Engineering
Kolhapur Institute of Technology's Institute of Management Education and Research