PANYAM VENKATESH

COPQ and VAVE Projects:

• Provided a solution to reduce relay scrap by optimizing socket design using 3DCS tolerance analysis, saving $71K annually
• Validated insertion force endurance through static structural simulation, successfully implementing the optimized design
• Recognized in the BU Global Innovation Awards competition, and prepared a guidebook on 3DCS
• Generated $75K in VAVE savings per year by replacing nut and washer combinations with flange nuts
• Resolved socket stud failure by optimizing housing design and implementing an additional keyway to withstand applied torque after performing RCCA
• Leading the localization of 150 coil variants of relays, involving teardown analysis and qualification
• Providing engineering support for the new product introduction of Kilovac LEV100/200 contactors in India

NPD Projects

• FC-360-201/200 Contactor: Designed and developed a 60A contactor with a mechanical economizer.
  Applied the DFSS approach, including VOC/PRD collection, QFD for converting customer requirements to functional requirements, and CTQ flow-down analysis for CVD
• Performed preliminary DFMEA to identify risks, and conducted development testing on existing contactors to determine margins
• Developed design concept models, and selected the best concept using the Pugh matrix
• Optimized design through vibration simulation to withstand robust vibration loads
• Prepared QTP for proto build and testing, filed a patent on the contactor's optimized design, and prepared a guidebook on vibration simulation
• FCC-390-CU4 Contactor-LEAP: Proof of Concept: Designed a 90A contactor within a 60A footprint
• Applied the DFSS approach and performed DOE for contact voltage drop using Ansys Optislang
• SSPC - Solid State Power Controller 75A and 150A: Designed busbars, housing, and baseplate
• Performed thermal simulation to identify temperature rise, and ensured REACH and ROHS coding compliance
• FC-360-100 Contactor: Designed a 60A contactor for 800 Hz and 105 °C, including coil circuit design for AC to DC conversion, and thermal simulations
• Designed a customized adapter as per customer requirements
• Updated documentation related to design specifications, procedures, and processes.

Engineering Change Management:

• Leading a team of six members for 3D modeling, drafting, and BOM creation
• Managed work assignments for engineers based on change requests
• Created technical drawings and schematics for production of products.
• Provided support throughout the entire product development life cycle from concept to launch

Technology Center Global Product Support Team GIS (245 kV to 420 kV):

• Creating part drawings, assembly drawings as per the ISO 2768, CAD data management by using CREO, PLM, and transfer to SAP ERP.
• Review, analyze, and implement product change requests (PCR) and customer change requests
• Collaboration with the global GIS support team.
• Performed burst pressure simulation for GIS modules using CREO simulation
• Applied DFM, DFA, and FMEA to the interlock panel
• Worked as the approver of the PPAP (Production Part Approval Process) globally for GIS parts.

NPD Projects:

• Interlock panel design for disconnector drive.
• Adapter design to connect Siemens and ABB bays.

Basic Design and Life Cycle Management of MCB, RCCB & Isolator:

• Performed modeling, detailing, and applied GD&T to parts and assemblies to simplify the manufacturing process
• Coordinated with the Quality team to resolve customer complaints regarding modular switchgear products
• Played a key role in executing design changes to comply with new revised standards
• Generated and executed cost-out project ideas in MCBs and Isolators through design changes, resulting in an annual benefit of 30L – 40L
• Prepared test plans for MCB, RCCB & Isolators for validation testing
• Conducted short circuit tests, analyzed, and resolved issues in switchgear products
• Managed Engineering Change Requests (ECR/ECN) and engineering documentation for design changes
• Responsible for the validation of molds and tools for products based on design and functional requirements
• Gained hands-on laboratory experience and domain knowledge in conducting Routine & Type Testing of modular Switchgear Products.

Participated in team for Designing of MCB (Miniature Circuit Breaker):

• Performed various engineering tasks involving analysis and design, working from instructions, drawings, proposals, specifications, and other pertinent information
• Reviewed and analyzed a variety of engineering data, documents, and reports
• Prepared design models for new projects using available design tools and programming, collaborating with sales, project management, and customers.
• Planned, conducted, and coordinated straightforward engineering analyses and tests, preparing related reports and summaries for review
• Assembled bill of materials and generated mechanical assembly and fabrication detail drawings
• Maintained drawing revisions by issuing Engineering Change Notices
• Developed standard mechanical design templates in collaboration with other group members
• Participated in the investigation of technical problems and the establishment of procedures and corrective actions to avoid recurrences