Pandi Raj Chinnappan
Chengalpattu,TN
Summary
A highly accomplished and strategic Mechanical Design and Development Engineer with nearly 10 years of experience driving product innovation in heavy machinery, auto components, and special purpose machines (SPM). Expertise in leading the full product lifecycle, from translating customer specifications into performance criteria to executing DFMEA, VAVE, and DFM strategies to achieve significant cost and quality optimization. Proven ability to leverage advanced CAD/CAE tools (Creo, CATIA, ANSYS) to deliver robust, high-performance designs, meet aggressive program milestones, and provide specialized technical leadership for continuous product improvement.
Overview
12
12
years of professional experience
1
1
Certification
Work History
Deputy Manager- Design & Development
Sharda Motor Industries Ltd.
Kancheepuram
12.2022 - Current
- Translate customer specifications and internal requirements into clear product performance criteria.
- Provide necessary inputs for designer to ensure that design meets the requirement.
- Support designer with regard to specifications knowledge and product robustness.
- Participate in DFMEA discussion and make sure relevant tests are specified in documents for effective analysis.
- Participate in design review, Implement best practice, processes and procedures to aid and improve product performance.
- Support design review and contribute to achieve internal milestones as well as customer program milestones.
- Identify and optimize design in terms of functionality, cost & manufacturability.
- Provide technical expertise to the team.
- Anticipates and overcomes obstacles.
- Contribute to continuous improvement activities.
- Quality control of work by appropriate reviews.
- Support and lead process improvement activities.
- Conduct benchmarking studies to determine best practices/designs and future trends.
- Perform root cause analysis and resolve problems.
Project Scientific Officer “C” Mechanical
Tata Institute of Fundamental Research-INO
Madurai
08.2019 - 12.2022
- Involved in the study and design of various mechanical elements and structures related to the 50kton electromagnet for the ICAL detector.
- Create a concept design and layout for Special Purpose Machines such as glass lifting machines, rotating fixtures, stackers for RPC handling, and so on.
- Design, drafting and component selection of a special-purpose fly cutting machine for Di-Counter polishing.
- Create drawings and designs for mounting fixtures for electronic chips and other precision components.
- Design and fabrication of jig and fixtures for Di-Counter(detector) manufacturing.
- Structural member selection and creating manufacturing drawings for the fabrication of the assembly work table for the CMVD wall assembly.
- Structural analysis for deflection and maximum stress induced using Ansys 18.1 Workbench for assembly work table, storage rack etc.
- Accountable for prototype development, updates/modifications, and follow up with the vendor for timely delivery of the components.
- Reverse engineering using Vernier Caliper, Height Gauge, CMM etc.
- Identifying, evaluating and managing vendors to support product development and prototyping.
- Planning, scheduling, and monitoring the fabrication of CMVD Wall detector components and assembly.
- Refurbishing, commissioning, and operating a spray painting machine, as well as conducting paint trials and inspections using destructive and nondestructive testing.
Senior Design Engineer
JM Frictech India Private Limited
Kancheepuram
05.2017 - 08.2019
- Responsible for concept design of wet brake system and its components for tractors, material handling and construction equipment’s.
- Perform force calculation for tractor brakes and its components.
- Carrying out DFMEA process for the New Product Design in CAM type brakes.
- Accountable for Design Calculation and Tolerance Stack Up calculation for brake assembly.
- Handled Reverse Engineering of dry and wet brakes for tractors and construction equipment’s.
- Implementing design updates for optimized manufacturing methods, considering the quality and cost.
- Material selection for casting components and steel plates etc.
- Carried out Value Added and Value Engineering as a part of cost reduction activities.
- Creating 3D models and complete detailing of the developed parts and its components using CAD Software such as Creo 4.0 and AutoCAD.
- Verification and testing of the newly developed products on field and at the testing facility.
- Creating process and maintaining drawings in PLM using WindChill.
Design Engineer
Caterpillar, India
07.2014 - 05.2017
- Company Overview: (Through Geometric Limited)
- Performing sheet metal and structure design for underground mining products and other heavy machinery by performing design validation through DFA, DFM and DFMEA.
- Responsible for engineering design changes, design and detailing of structural components of boom, feed, carousel rod changer and dust collecting system and light fabrication using Creo 2.0.
- Contributed to full machine conversion of Bucyrus machine to Caterpillar based on current design standards.
- Carrying out design calculation, member selection, load calculation etc.
- Defining weld parameters for large assemblies like platform assembly, handrail assembly, frame assembly etc.
- Design and drafting of sheet metal components in the drill machine such as tank assembly, rear frame, hood, headboard and enclosure.
- Accountable for design changes caused due to the CPI (continuous product improvement) issues on field.
- As a part of cost reduction activity, implemented new design changes to the existing components.
- 3D modeling and 2D drafting for sheet metal components using CAD software and applying GD and T as per ASME Y14.5 2009.
- Created individual parts and handled large assemblies using both Bottom Up Assembly and Top Down Assembly approach.
- Estimating and scrutinize the required raw material to carry out fabrication/production.
- Preparing production drawings, provide cutting plans to the production team.
- Addressing major production problems, ensuring optimum manufacturing methods and techniques for new product development.
- Contributed to successful release of: MD5150C Track Drill Machine, MD5075C Track Drill Machine (New Product Improvement), 584 HD Forwarder, MD5050 Track Drill Machine
Engineer Trainee
Myunghwa Automotive Pvt. Ltd.
Kancheepuram, India
05.2013 - 05.2014
- Involved in design and detailing of auto parts such brake drum, sheet metal brackets, brake hub, input shafts etc.
- Implement VAVE and cost reduction to optimize as part of new product improvement.
- Provided CAD Support for prototype using CAD tools.
- Handled responsibilities of coordination, follow up with production and ensured timely delivery.
- Involved in reverse engineering and application of basic GD & T and Bill of Materials generation.
- Using PLM software’s for drawing release and drawing maintenance.
- Creating engineering drawing notice and revision updates in the drawing.
Education
Master Diploma - Product Design and Analysis
CADD Centre
Bachelor of Engineering - Mechanical
Vels University
01.2013
Skills
- Product Design
- Design Failure Mode and Effects Analysis
- Reverse Engineering
- Product prototype development
- Geometric Dimensioning & Tolerancing
- Tolerance Stackup Analysis
- Value Analysis & Value Engineering
- Costing Bill of Material
- Design for Manufacturability
- Catia V5
- Creo Parametric 50
- Solid Works
- Ansys 180
- PLM / Product Lifecycle Management
Accomplishments
- Achieved [Result] through effectively helping with [Task].
Certification
- CPM - Certified Professional Manager
Other Details
Tamil, English, Hindi and Telugu.
Awards
Geo Champ Award for generating revenue of $137750 to the company., Caterpillar Supplier Summit Annual Award for going beyond and achieving superior results for organization in the year 2015., Spot light award for successful completion of projects on time., Won 2nd prize in the Analysis event in Madras Institute of Technology., Won 3rd prize in the CAD Design event in Madras Institute of Technology.
Hobbies and Interests
Swimming, collecting coins and listening songs
Timeline
Deputy Manager- Design & Development
Sharda Motor Industries Ltd.
12.2022 - Current
Project Scientific Officer “C” Mechanical
Tata Institute of Fundamental Research-INO
08.2019 - 12.2022
Senior Design Engineer
JM Frictech India Private Limited
05.2017 - 08.2019
Design Engineer
Caterpillar, India
07.2014 - 05.2017
Engineer Trainee
Myunghwa Automotive Pvt. Ltd.
05.2013 - 05.2014
Bachelor of Engineering - Mechanical
Vels University
Master Diploma - Product Design and Analysis
CADD Centre