Sashanka Pilla

• Used critical thinking to break down problems, evaluate solutions and make decisions.
• Used strong analytical and problem-solving skills to develop effective solutions for challenging situations.
• Improved internal knowledge sharing by developing comprehensive documentation outlining standard operating procedures for various tasks.

Professional Summary:

• Develop SOP and targets for chassis related attributes.
• CAE Sign off responsible for chassis projects evaluated at supplier.
• Mentored junior staff members on best practices for project management and team collaboration skills, fostering supportive work environment.
• Benchmarking studies of competitor vehicles features and their effect on durability performance.
• Negotiating work scope and PO with supplier to develop virtual road load data schedule and loads for aid in product cycle development.
• Misuse load cases development (obstacle identification with speed and braking definition) for chassis and battery pack development

Significant Projects:

• Wheel Bolt Fatigue Test is simulated to root cause transversal bolt failure observed on bolts during cornering fatigue test. Failure location co-related and countermeasure provided.
• Rear Door Slam Durability is one of the important durability tests in door design and development. Door requires to meet certain performance requirements like it should close properly (no metal to metal contact), there should not be any leakage, and closing operation should be smooth & with minimal effort and it should survive the life of the vehicle (cycles).
• Rear Door Sag set & Over bending are performed as part of door score card assessment, where door sag is carried out at different opening angles and Over bending is simulated at full open condition. The objective of both the cases is to ensure the door latches after the operation.
• US Rear trailer hitch assessment is carried out as per SAEJ684 standards
• Cargo secure lashing points strength assessment is carried out as per ISO27955 (Passenger car) and ISO27956 (Pickup trucks and vans)
• BLNV test - Front Knuckle failure root cause analysis is performed using critical plane identification approach and providing design countermeasure.

Professional Summary:

• SPOC for Front Suspension Durability Team, Responsible for Project management activities related to unibody programs.
• Provided extensive support to several product engineering groups at Chrysler Technical Center, Auburn Hills, Michigan, USA for Front Suspension System, Sub Systems & Components development for all ongoing vehicle programs during Liaison tenure from July2014 – Sept2015 & September 2019 – March2020
• Root cause analysis, Enabler identification, Cost reduction through product and process optimization.
• Test to CAE Co-relation activity to establish CAE confidence to reduce product physical testing.
• Demonstrated strong organizational and time management skills while managing multiple projects.

Significant Projects:

• Vehicle Washout, where objective of project is to simulate and evaluate front suspension and wheels in loading scenario where vehicle enters a trench or pothole at rapid deceleration.
• Suspension Misuse/Articulation Study, where objective of project is to simulate and evaluate suspension for Abusive and Generic load scenarios.
• Chassis Durability Assessments, where linear and Non-linear analysis are carried out on suspension components such as knuckle, control arms, lower and upper links, cradle, shock assembly. etc., against road load data and abusive load data and analyze performance for fatigue life and strength criteria.
• Chassis Joint Integrity Assessment, where Non-linear analysis are carried out on suspension attachments with bolted connections against road load data, joint slip is monitored against target, bolt is analyzed for fatigue cycling and spacers are checked for strength requirements.
• Chassis components optimization, where Topography and shape optimization techniques are applied on suspension components like knuckle, control arms and links to either achieve weight savings or stiffness optimization.
• Test Bogey development from Road load data, where objective of project is to develop Test Bogey’s (Block Cycles) from road load data (time domain) and provide to testing community to evaluate suspension components. Assess damage content from time domain data, create a sine wave data based on lab requirements, assess damage content of constant amplitude, calculate number of cycles required for damage equivalence, create equivalent damage test bogey
• Virtual Mechanical life testing simulations, objective of the project is set up and perform virtual DVP&R test items for suspension components. Reduce component total development cost by reducing the physical testing. Compare the DVP&R test items hotspots against time domain data hotspots and eliminate the test setups which does not highlight similar hotspots.
• Time domain data manipulation using nCode, objective of the project is to manipulate time domain data using nCode glyph works to carry aid CAE simulations or for root cause assessment. Manipulation of time domain data include, sim min-max extraction, level crossing, rain flow counting, load transformation from one vector system to other another vector system. Load splitting.
• Progressive Die Rack CAE strength assessment, where failure mode of Die rack during stamping operation is captured using CAE tools, root cause analysis carried out and design enabler is proposed and implemented.
• Engine system durability using PSD data, objective of the project is to carry out fatigue life and strength assessment's for engine system components like CAC, exhaust hangers, fuel straps against the provided PSD data.