Madhu Somana
Hyderabad
Summary
Dynamic Sr. Design Engineer with a proven track record at QuCev Technologies and HL Mando Anand Pvt Ltd, specializing in EV commercial and passenger vehicles. Excelled in cross-functional collaboration and problem-solving, significantly reducing parking brake system costs by 67%. Expert in Proto typing, Bench Marking , Validation & Expert in design by using Creo & Catia V5 with outstanding presentation skills.
Overview
6
6
years of professional experience
1
1
Certification
Work History
Senior Design Engineer
QuCev Technologies
Hyderabad
10.2023 - Current
- Company Overview: Qucev Technologies is an EV startup by Ex Oletra Team.
- The Major Projects are 3.5T Commercial Truck & Passenger Van Segment.
- Handling Service & Parking Braking System
- Responsible for performing a key role in entire Braking system selection , design calculation, material selection, Vendor Selection , Validation & Homologation (CIRT & GARC) as per AIS & IS Standards.
- Based on Design requirement, Creating SOR & RFQ.
- Vacuum Pump VCU related SOR also created.
- Responsible for creating a APQP, DFMEA & DVPR Other design related documents.
- Design Calculations done for Vehicle level Stopping distance, gradeability, Volumetric analysis & Pressure distribution analysis.
- Responsible for creating a E- BOM, EO, ECN, & PLM (Wind Chill) Activities
- Responsible for ESK & SOP documentation for CFT Team
Responsible for Preparing service catalogue or Manuals for all dynamic components & documents created for preventive maintenance schedules. - Integrating the Supplier Components for Package the braking system, these parts developed along with vendor development (brake valves, Bundy pipes, sheet metal parts, brake drum, rubber hose, parking cables, parking lever, Parking equalizer, brake pedal bracket, vacuum tank, etc.)
- Product benchmarking with other competitors
Negotiated with vendors to secure advantageous terms for prototype fabrication, expediting the product development cycle. - Optimized existing product designs for manufacturability, sustainability, and compliance with industry standards.
Collaborated effectively with design and prototyping teams, improving product development and delivery speed. - Utilized CAD software to create detailed engineering drawings and 3D models for complex mechanical components.
- Used impeccable communication skills to convey complex technical engineering concepts to non-technical stakeholders.
- Making Counter Measure documentation for each & every Concern raised by Validation & Field Issues along with CFT Teams.
- Responsible for Vehicle dynamics development program in the field of Braking & Other Aggregates Like Steering Front & Rear Axles.
- Providing a design & product trainings for CFT team
- Major Validation issues faced during validation are Brake Judder or pulsating , Spongy Pedal or excessive travel , Brake Pedal Hard (Excessive Pedal effort), Grabbing or Pulling brakes, Over Heating & Wheel Jam ,Brake Roughness or Chatter on , Brake Binding , Over Heating Of drum brakes ,Brake Noise, TUK - TUK Noise , RATTLE Noise , Poor braking.
- Brake fade Measurements done by using Chase fade machine.
- Performed VA, VE Activities (at Initial Parking Brake System Cost of ₹3,000 to ₹990 per vehicle
Design Engineer
HL Mando Anand Pvt Ltd
Chennai
06.2019 - 09.2023
- Company Overview: HL MAIL is a leading manufacturer and supplier of high-performance electrical Power steering, Mechanical steering Gear, (DPEPS) IDB, ABS, EBS, Actuation Brake systems, shock absorbers and struts for Indian, European and American OEMs
- Major Customers include Kia, Hyundai, Maruti Suzuki, Ford (Global OEMS), Tata Motors, Mahindra & Mahindra
- Study of SOR and Understanding Customer Requirements
- System to be Designed Based on regulation of FMSS/ECE/IS
- Preparation for E-BOM Based on available Variants
- Preparation for PRE-Tech Review & Consolidated study on Design Factors
- VA, VE Ideas to be developed for Cost Reduction
- Preparation for RFQ for awarded Projects
- Good knowledge in 3D modelling, 2D drawing and assembly
- DFMEA, APQP Prepared for New projects
- BOM Creation & Gate Entry review to be created
- Based on Customer Timeline Design to be fixed & all Drawing to be released thru PLM (Integrated Product, Process, Collaboration system)
- Closely Monitoring to Supplier Tooling Kick off for new Designs with Streamlined to Customer Timeline
- Close Monitoring to In House Production Engineering Team for Tooling Kick Off & Line Readiness for PPAP & SOP
- Based on Customer Timeline Initial Design Proto to be conducted and Recorded the Open Issues & Meeting to be conduct with CFT Teams to resolve it
- Proto Samples Validation to be Conduct in HL Mando along with Research & Validation team
- Production validation and Design validation sample test be conducted Based on Test Results Meeting to be Conduct Frequently with Customer if any Design changes (Such as like Packaging Constraints, Size of the products, Weight of the Product So on …) to developed and updated based on target time
- ISIR Preparation for Tech Approvals
- Developments Stage Samples handover to customer for Checking the Feasibilities & Product Specifications
- ECO & EAR OR ECN Task performed
- 4M Change Management with regarding Design accept (Such as Material Change …) to be recorded.
- Global Product Transfer Activates and Creating Master Drawings for all other regions like China, Korea, Mexico & America
- Monitoring the SOP Project issues regarding design related issues
- Creating a documentation material for supplier portfolio (Supplier Manufacturing Process & Technology) Which leads to understand to newcomers for easy to design a product
- Creating Design standards to make a Proper design
- Creating a lesson learned and conduct meeting to design teams for knowledge transfer
- Conducting a training for newcomers about PLM, and other HL Mando internal Software's
- In house production open issues regarding design to be solved
- Regarding quality issues Frequently Visiting supplier lines to observe the challenges facing by them and make it overcame by team effort along with suppliers' team
- Imported Raw materials (CKD) to localization (LP) with equivalent grades
- Creating a Technical study Material for IDB (Integrated dynamic brakes)
- Vehicle level BSTR & IDB Trails Performed.
- Visiting the customer end to identify the Trouble shooting, based on their feedback along with customer and HL Mando Teams in line work to solve the issues.
- Conducting weekly meetings with CTO, HOD & HOT's regarding project timeline and updating current project status.
- With regarding Test team monthly plan to be share for testing team.
Education
B-tech - Mechanical Engineering
B.S. Abdur Rahman Crescent Institute Of Science And Technology
Chennai India01-2023
Diploma - Mechanical Engineering
M.B.T.S GOVT POLYTECHNIC
Guntur Andhra Pradesh01-2018
SSC -
GOVT HIGH SCHOOL
Chodavaram Visakhapatnam 01-2015
Skills
- Design engineering
- Brakes domain
- EV commercial and passenger vehicles
- Product Design and Development
- Cross-functional collaboration
- Problem-solving
- AutoCAD
- Creo Version 10
- Catia V5
- Prototyping
- APQP, DFMEA, DVPR, and E-BOM
- GD&T
- 3D modeling and 2D drawing
- System Sizing and Packaging
- Vendor selection
- Homologation and certification at GARC and CIRT
- Presentation and Communication Skills
Certification
- Certificate for excellence in Problem solving Procedures (PSP-8D), Grade -1, Best Team leader
- Certificate for excellence in MS-Office PowerPoint, Grade -1, Best Team leader
Accomplishments
- Best Quality consciousness Award for Diaphragm leak issues
- Best Communicator & Presenter Award by Bija
- Best Team Leader
- Factory Innovation Award
- Achieving Second Prize in safety Poster By MAIL
- Certificate for excellence in MS-Office PowerPoint as Grade -1 & Best Team leader by MICROSOFT CERTIFIED Trainer
- Problem Solving procedure (8D) first prize
- Synergic force award for Best designer team of the quarter
- Shining Star Award for Best Team Leader of the quarter
Major projects handled
- Actuation brakes for TATA,M&M,HMI,KIA,MSIL
- IDB assembly, M&M, TATA, India
- Brake System for Q.C 3.1
- ABS Brake System for Q.P 3.2
Work shop training
- Problem solving procedure (QR, 4D & 8D)
- Safety Training
- 7QC Tools, Visual & Time Management
- Communication & Presentation Skills
- DFMEA Training
- Destructive & Non-Destructive testing workshop held in college campus
- Forging, Welding, Casting, & Carpentry workshop held in college campus
- Supplier visits for better understanding the manufacturing Sheet metal, Rubber, Plastic, Casting, electronic Switch & Fastners Components
- Vehicle level testing for identifying the sharp, Smooth & Hard braking
- Catia V5, 3D experiences, Creo 9.0, Auto Cad 2D, PLM (ENOVIA & Wind Chill)
- Flashing Software through CANOE for IDB, ABS & ESC
- ABS, EBS & IDB Performance checking at MSPT (M&M SUV Proving Track) & GARC
Personal Information
- Age: 25
- Father's Name: Satya Rao Somana
Languages
Telugu
First Language
Tamil
Advanced (C1)
C1
Hindi
Advanced (C1)
C1
English
Advanced (C1)
C1
Disclaimer
I am confident of my ability to work in a team efficiently and effectively. I do hereby declare that the information contained herein is true and correct to the best of my knowledge and belief.
Timeline
Senior Design Engineer
QuCev Technologies
10.2023 - Current
Design Engineer
HL Mando Anand Pvt Ltd
06.2019 - 09.2023
B-tech - Mechanical Engineering
B.S. Abdur Rahman Crescent Institute Of Science And Technology
Diploma - Mechanical Engineering
M.B.T.S GOVT POLYTECHNIC
SSC -
GOVT HIGH SCHOOL
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