Nikhil Saggam

Hospital Patient Monitor Design:

• Lead mechanical design of critical components for hospital patient monitors, ensuring patient safety and reliable system operation.
• Troubleshoot and resolved injection molding issues related to ejector marks for a plastic component, optimizing production efficiency and quality.
• Spearheaded rapid prototyping of plastic components using FDM technology, accelerating design iterations and early stage decision-making.

• Led a $9M+ program, slashing heavy-duty diesel NOx emissions by 90% via a patented rack & pinion cylinder deactivation system. Revolutionized V8 pushrod engine NOx emissions. My innovative approach earned me the company's Outstanding Technology Award.
• Invented novel hydraulic flow system to ensure consistent oil distribution on all rocker arms, all within the existing V8 pushrod platform.
• Championed Design for Manufacturing principles, delivering a 10% cost reduction and hitting client's target head-on.

• Led development and implementation of cutting-edge Engine Brake program for prominent Japanese OEM, driving project success from concept to testing.
• Designed and maintained crucial project documentation, including boundary diagrams, P-diagrams, DFMEA, and DVP, ensuring clear direction and risk mitigation throughout development process.
• Mentored new engineers on advanced analytical techniques for Variable Valve Actuation programs, empowering them to tackle complex engineering challenges and contribute effectively to projects.
• Deployed to Michigan, USA, tackled engine brake issues in a type-3 valve train system by solving the critical problem of breaking plungers on rocker arms. My solution earned high praise from the customer.

• Proactively identified and resolved critical clearance issues in the cylinder head for an Engine Brake program through meticulous tolerance stack-ups and insightful Monte-Carlo simulations for a heavy duty diesel truck, ensuring optimal component fit and system performance.
• Mastering the 8D methodology, pinpointed a rocker arm failure's root cause and implemented a lasting solution, preventing future occurrences and showcasing adept engineering problem-solving.
• Developed a comprehensive VVA engineering standard for streamlined design and fostered knowledge transfer, becoming a valuable benchmark within the company.