Tadi Maruthi Ganesh

1. Part Feasibility and Tooling Analysis: Engineered comprehensive tooling solutions, conducting feasibility assessments and Mold Flow Analysis, optimizing part design and reducing lead times & determine the required number of tools, Choose molding machines and mold sizes, design strip layouts, determine Press tool types (progressive or stage), and identify necessary fixtures for projects.

2. Collaborative Design and Development: Design and develop various tools, including injection molds and stamping tools, for electromechanical products. Work closely with the Product Design Department on Design for Manufacturing (DFM) and modification activities.

3. Leadership and Team Management: Lead a team of Tool Design engineers, providing technical guidance to ensure high-quality, error-free engineering outcomes on the first attempt. Establish team priorities, maintain schedules, monitor performance, conduct performance evaluations, and provide constructive feedback.

4. DFM Reports and Documentation: Review and create DFM reports for molds, stamping tools, and components made from plastic and sheet metal to ensure manufacturability. Develop comprehensive technical documentation for each tool design project.

5. Tool Performance and Optimization: Enhance tool performance by implementing innovative design concepts. Reduce manufacturing costs through strategic optimization of tool designs for improved efficiency and production rates.

6. Project Management: Successfully manage multiple projects concurrently from concept through execution, ensuring timely completion within budget constraints. Demonstrate exceptional time-management skills and attention to detail.

7. Quality Improvement: Increase product quality by analyzing tooling functionality and identifying areas for improvement. Reduce scrap rates through diligent monitoring of tool conditions and timely replacements.

8. Cross-Functional Collaboration: Collaborate with electrical, electronics, and product engineers to meet quality and performance standards. Work closely with vendors to create prototypes for testing and validation.

9. Tool Modification and Troubleshooting: Modify existing tools based on changes in functional requirements, customer feedback, manufacturing inputs, or performance improvements. Troubleshoot complex tool design issues to ensure minimal downtime.

10. Continuous Improvement and Cost Reduction: Support continuous improvement in product development, manufacturing, and customer service. Proactively identify and implement cost-saving solutions, including material usage analysis and tool design standardization.

11. Training and Development: Lead training sessions on the use of newly designed tools, ensuring safe operation and optimal performance among team members.

12. Documentation and Communication: Prepare and maintain documentation across various design and development phases. Establish effective communication with vendors and suppliers to ensure timely delivery of materials.

13. Projects: Designed tools for UL98 disconnect switches and accessories, high-density terminals and shorting blocks, miniature circuit breakers (MCBs), and developed product and tool designs for bus bars and accessories.

14. Machines: Designed tools for molding machines ranging from 22T to 200T and for press machines from 10T to 63T.

15. Software Proficiency: Utilize key software tools including Autodesk Inventor 2021, Moldflow Advisor, and AutoCAD 2021 to support design and analysis activities

1. Collaborate with the Product Design Department on Design for Manufacturing (DFM) considerations and modification activities.

2. Acted as the primary interface between the design team and suppliers, providing support in all relevant activities.

3. Prepare initial feasibility reports and address DFM feedback from suppliers.

4. Manage RFQs: Identify and select suppliers for tool development, negotiate costs, and establish project timelines for tool development.

5. Explore new tool manufacturers and negotiate to ensure the use of optimal raw materials. Optimize processes by reducing the number of operations and stages while adjusting relevant process parameters.

6. Conducted evaluations of tool/die/mold, fixtures, and gauge concepts, granting approval for tool manufacturing.

7. Monitor and track tool development schedules closely with vendors, ensuring timely progress and resolving any arising issues promptly.

8. Attend trials, provide feedback on part-related issues, set action plans for subsequent trials, and monitor progress.

9. Conducted Tool and Component Process Design Inspections (PDI) to ensure quality and cost compliance, establishing tools for mass production.

10. Managed new product/tool development for sheet metal, plastic, and EPS parts, ensuring smooth handover to the plant.

11. Coordinate with plant and new product development teams to ensure timely project implementation.

12. Tooling ERP: Digitize tool management through SAP to track tool life and history, identifying and mitigating risks related to tool life and duplication.

13. Manage contract-related tasks, including developing confidentiality, bailment, and commercial agreements with suppliers.

14. Key Projects:

· AC 22 ODU, 18" IDU & Side Grill for Deep Freezer: Successfully completed RFQ, DFM, T0/T1 at the vendor site, production trials at the supplier site, and approval at the manufacturing plant.

· Water Cooler & Deep Freezer: Completed RFQ and DFM stages.

15. Key Software: Creo 3.0, AutoCAD 2019, SAP ERP.

• Detailed Study of New NPD parts & their critical characteristics & Customer Requirements
• Product Design, Material (Equivalent /Alternate materials), GD&T Review & Discussion with Customer to Improve the Part Formability & Manufacturing Feasibility
• Preliminary Process Flow (Stage Tool Concept, Progressive Tool Concept Strip layout, Load Calculations for each station/Operation (Blanking, Piercing, Forming, Drawing, Bending), Press Selection
• Dimensional & Measurement Feasibility Study of new stamping products
• One-Step (Inverse) Analysis using HYPERFORM 12.0 for optimizing the Blank Size in Comparison with Forming Theoretical Calculations & By Volume method (using CREO 2.0)
• Incremental Analysis done using Sheet Metal Formability Analysis Software Altair HYPERFORM 12.0 for various Operations (Drawing, Bending, Coining) of Different Parts to predict/ study about the Metal Forming Behaviors & failure criteria (Thinning , Thickening/Gathering , Stress/ Strain , Wrinkling ) with respect to the Tool Design Parameters
• Final Tool design (which includes Progressive Tool, Stage Tool (Compound Tool, Combination Tool, Cut & Carry Tools) & Detailing done for the respective parts (AUTO parts, Stamped Parts & Cages (Taper,Cylinder,Spherical))using Creo 2.0 with consideration of the Incremental Analysis Results
• Tool Design of Inspection Gauges & maintaining of existing tools
• Support to Tool Room in Manufacturing of critical, regular Tool parts & Inspection
• Production / Trail Follow up & Trouble shooting of the problems faced & Discussion with the Manufacturing & Production Team for further improvement of the Tool Production (To increase OEE %)
• Analyzing / To Study the results observed & comparison with Hyper form Analysis
• Key software: Creo 2.0, Hyper form 11 & 13

• Sheet Metal & Plastic Product DFM Review with Product Design (PD) Team for automobile parts
• New product Development and 3D modelling of Plastic Parts
• Plastic Injection Molding - Detailed Study of the Properties & Drawing of part, Checking Feasibility, deciding parting line, No
• Of cavities, Type of Gate, Cooling
• Calculations, Core Cavity Extraction, Designing Suitable Molds Base, Electrode Extraction Etc
• Tool designing of Press Tools & Inspection Gauges for sheet metal components & Robot welding fixtures
• Developing and Modification of existing tools
• Coordination with the Manufacturing Team for the Concerns detected on stage
• To interact with the Stores and Purchase Dept regarding Raw Materials and standard materials
• Key software: UG NX 9.0, AutoCAD 2013

• High Pressure Die Casting die for 200 cc CNG Mega clutch cover for Three-Wheeler
• Designed a HPDC die for 3-Wheeler Clutch cover with economic cost of manufacturing by considering the critical parameters involved in the die casting design process & manufacturing resources available, to meet all the R&D requirements
• Designing and detailing the die is done using Unigraphics NX7.5
• Updating Casting drawing for 2-Wheeler clutch cover
• Modification of existing die
• Detailed drawings of parts for manufacturing
• Key software: UG NX 7.5, AutoCAD 2013