Summary
Overview
Work History
Education
Skills
Accomplishments
Affiliations
Additional Information
Timeline
Generic

Vikas Singh Sawan

Bengaluru

Summary

Meticulous Automotive R&D Professional (CAE Engineer) who excels at juggling multiple tasks and working under pressure. Broad industry experience includes Passenger Cars, Commercial Vehicles, Electric Vehicles, Industrial Products with strong leadership skills. Highly Experienced, Technical, Team oriented Leader with excellent project management skills who works effectively with all levels of employees in cross-functional teams.

Overview

13
13
years of professional experience

Work History

Manager - CAE Structures (Program Lead)

OLA Electric Technologies
07.2021 - Current


  • Conducting complex simulations using LS-Dyna and OptiStruct to evaluate and enhance the structural performance of component and systems
  • Utilizing OptiStruct for design optimization, collaborating closely with design teams to achieve lightweight, robust, and cost-effective structural solutions
  • Process improvement plans, DVP Preparation and execution with the team to reduce the manual effort during execution of projects
  • Technical assistance to team members and team leads during analysis of various automotive domain projects like Crash & Safety, Strength & Durability, NVH, Stiffness and Interior CAE
  • Resource Management for CAE/CAD & Product development verticals
  • Applying skills to advance the structural integrity of automotive components, ensuring compliances with safety standards and contributing to the evaluation of next generation vehicles
  • CAE Methodology development and creating standard operating procedures
  • Collaborating with multidisciplinary teams to integrate CAE insight seamlessly into the product development process, fostering innovation and efficiency
  • Preparing and releasing analysis report with CAE risk assessment to provide feedback to design team and cross functional teams to highlight the performance target achievement with improvement required
  • Plan for necessary components and system level test for CAE correlation.
  • Different Explicit analysis done on LS DYNA Explicit. Eg: Drop test, Snap Analysis etc…
  • Handled big models having 5 million DOFs and extensive nonlinearity in terms of geometry, material, Bolt Pretension, Contacts etc.
  • Optimization of Swing Arm, Fork Arm, Powertrain Components (Target : 20% weight reduction) using OptiStruct with different functionality and design criteria
  • Structural Battery Simulation during high speed impact
  • Initiate technical discussions with design, styling and cross functional team understand their need for Structural validation
  • Interpret results for different load cases, find fatigue & yield safety factor for components, perform Design Modifications as per need and validate those modifications.
  • Working as SPOC / Co-coordinator and get work done from CAE Project Team.
  • Review & Interpret work done by project team and discuss results with CFT for design improvements and modifications.
  • Prepare project specific technical documentation like Scope of Work (SOW), Understanding Documents and Technical Proposal etc.
  • Guide and develop project team as per management guidance.
  • Handled whole project life cycle. i.e., Receive 3D model from design center > Meshing > creation of load cases as per standard> FEA calculation before test> Find high stress regions> gauge placing> Static & Field test> …> Validate the final modified design.
  • Used advanced CAE techniques like: Design Optimization, Adaptive meshing etc.
  • Done different type of analysis like: Linear and Non Linear structural analysis, Dynamic analysis.

Senior CAE Engineer

Gestamp Services India
11.2014 - 06.2021
  • Worked on full vehicle program for Frontal, Side and Rear Crash loadcases for various OEM with Gestamp Cold Stamp & Hot stamp solutions.
  • Deck set up for various regulations, model checks using CAE software’s like Primer and HyperWorks etc
  • Full Vehicle Analysis with CAE Test Correlation for various OEMs
  • Carried out component level analysis for various subsystem like Lower control arm, Front suspension and for Door assembly
  • Responsible for Crashworthiness development of vehicle structure concept for vehicle program for lightweight solutions.
  • Involved in feasible B-pillar design recommendations to implement design changes as required to achieve B-pillar performance.
  • Carried out NVH and the Stiffness calculations for full Vehicle BIW using Optistruct/ Nastran.
  • Performed optimization studies by utilizing optimization CAE tools, to optimize B-pillar designs to meet performance requirements while minimizing mass and cost.
  • Responsible for report preparation for all CAE analysis results using CAE post-processing tools.

Senior CAE Engineer

Honda R&D Center
11.2014 - 12.2015
  • Lightweight parts development of Honda Accord program - It covers Modeling, Integration, Crash analysis for Vehicle Structure, Making of Design Proposals, Apply Model Check, Design Optimization & Report Preparation and Discussion with Japanese Engineers
  • Worked in Side crash team to develop the light weight B-pillar solution for Honda Accord.
  • Performed various side crash simulations to meet the legal and consumer regulations in Japan and USA.
  • Responsible for Crashworthiness development of vehicle structure concept for vehicle program (Side Crash) for lightweight solutions.
  • Involved in feasible B-pillar design recommendations to implement design changes as required to achieve B-pillar performance.
  • Performed full vehicle and sub-system crashworthiness CAE on passenger vehicle programs.
  • Involved in developing body structures to meet safety standards.


CAE Analyst

Satyam Venture Engineering Services
06.2012 - 10.2014
  • Worked on full vehicle program and supported to frontal crash team for OEM’s.
  • Performed model build for various regulations, model checks using Oasys Primer, Hypermesh macros provided by the client and analysis using CAE soft wares like LS-Dyna
  • Full Vehicle Frontal Analysis with CAE Test Correlation
  • Full Overlap, 40% and 25% Offset Front Impact Analysis as per IIHS
  • 40% Offset Front Impact Analysis as per Euro NCAP
  • Unit analysis for various design changes in Lower control arm in Front suspension and for door assembly.

CAE Engineer

International Automotive Components (IAC)
10.2010 - 06.2012
  • Carried out FE modeling for Interior parts like IP, Door, Consol, AC Grills etc.
  • Carried our FE modeling for Seating and transmission system using Hypermesh.
  • Model Analysis, Linear static and Thermal Analysis of Instrument panel and Door.
  • Door sag analysis using various boundary conditions at Hinge location.
  • NVH and structural Analysis of Instrument panel,Door.
  • Report preparation for Structural and various Linear Static analysis.

Education

MBA - Marketing Management

Department of Management Sciences (PUMBA)
Pune
07.2021

Bachelor of Engineering - Mechanical Engineering

Kavikulguru Institute Of Technology And Science
Ramtek (Dist.-Nagpur)
07.2009

Skills

  • Expert in CAE Crash & Safety, Structural Simulations & Optimization, Product development, VAVE Proposals
  • Proficient in Altair Products (HyperWorks, OptiStruct, LS-Dyna, HyperCrash Non Linear Implicit & Explicit) (10 Years)
  • Proficient in LS-Dyna Implicit & Explicit (10Years)
  • Good knowledge in Automotive Benchmarking and Lightweight Solutions
  • Proficient in Project & Program Management (5 Years)
  • Good Experience on both BIW and Chassis components along with sub system & full system level Analysis for ICE and Electric Vehicles
  • Good at Project Co-ordination and Leadership activities like: CAE Methodology Development, Data Management, Productivity Improvement, Time management, Project Planning and Presentation skills

Accomplishments

Total 13+ Years of Experience as CAE Engineer in different domains

  • Currently Working as Manager- CAE Structures ( CAE Program Lead, Vehicle Engineering ) since 2.5+ Years in OLA Electric, Bengaluru
  • 1.5+ Years worked as CAE Onsite Lead in Honda R&D Center, Japan
  • 3 Months worked as CAE Onsite engineer in Mazda Corporation, Japan
  • Worked as CAE Engineer/Project Lead/Project Manager for different domains like: Passenger Cars, Sport Utility Vehicles (SUVs), Scooters & Motorbike, Electric Vehicles
  • Automotive OEM Experience like Ford, Tata Motors, Mahindra, Volkswagen including onsite experience at Mazda Motors, Honda R&D Center, Japan


Key FE Analysis/Product Development Projects Handled

  • Component, Sub System & Full System level FE Analysis on Automobile & Vehicle Structures
  • Executing and managing CAE projects involving Crash & Safety, NVH, Stiffness Analysis, Strength & Durability, Interior CAE, Topology & Topography Optimization, Powertrain Engineering for Passenger cars and Commercial Vehicles (2W, 3W & 4W)
  • Experience working from concept design to SOP
  • NVH and Stiffness Calculations in Different full vehicle passenger cars, scooter and motorcycle analysis (Modal, Static, Dynamic)
  • Component, Sub System & Full System level FE Analysis and design proposals on Automobile & Vehicle Chassis and other structural components (BIW, Frames, Suspension parts, Swing Arm, Chassis, Wheelrims) using LS-Dyna, OptiStruct and HyperWorks package
  • Worked on dynamic and some other quasi static Analysis for different load cases for vehicle structures
  • Worked on Non Linear Contact Analysis along with Correlation with physical test
  • Worked on Explicit analysis like: Drop Test, High Speed Impact Crash Simulation etc
  • Sub Modeling of Wheel, Chassis, Drive line assembly to perform detailed study and optimization of different component with Full system level loadings
  • Perform and handle different Optimization projects on Optistruct
  • Perform Bolt analysis for the Wheelrim and Vehicle Structures
  • FE Analysis/ Fatigue Life Calculation/ Correlation of FE Results with Actual Test/ Product development/ Design Calculations/ Design Iterations for various OEMs for lightweight solution
  • FE Analysis & Meshing of different components of Car, Auto, Scooter & Motorbike


Key Achievements as Project Co-ordinator (SPOC) / Manager

  • Being in Automotive Industries 4+ years of total experience in Project & Program Management
  • Managed and Co-ordinate team size from 2 to 30+ team size
  • Implemented different CAE Methodologies in project for continuous improvement
  • Always work on project delivery and CAE driven solution
  • Spend 3000+ hours only in project management

Affiliations

  • Certificate Course in "Introduction to Python Programming" (Udemy)
  • Attended 1 Week HyperWorks advanced Workshop for Solver Technique at OLA Electric premise
  • Attended 3 Days LS-Dyna advanced Dynamic analysis Training
  • 2 days basic training on Structural Optimization using OptiStruct
  • 2 days basic training on Vehicle Benchmarking platform (a2Mac1)

Additional Information

Rashtrasant Tukadoji Maharaj Nagpur University, Nagpur

Department of Management Sciences (PUMBA), Savitribai Phule Pune University

  • Activities and societies: Entrepreneurship Development | Paper Presentation | Debate Team | Business Case Study | Storyteller | Marketer | Product and Service Marketing | Business Branding | Business Strategy
  • Participated in multiple activities
    ✓ Presented Startup Idea for college group presentation.
    ✓ Participated in the discussion on Harvard Business School case studies on management decision making.
    ✓ Active member of our Marketing batch for various product and service marketing presentations.
    ✓ Case study and report presented on Digital Marketing.
    ✓ Participated in business case growth discussion


  • Activities and societies: Engineer Projects | Paper Presentation | Social Worker | Team Work
  • Active member in collage technical and cultural festival organizing committee
  • ✓ Active member of our Mechanical Engineering batch for various college activities and competitions.
    ✓ Career Guidance for Juniors.
    ✓ Helping Hands Group for social work.


Timeline

Manager - CAE Structures (Program Lead)

OLA Electric Technologies
07.2021 - Current

Senior CAE Engineer

Gestamp Services India
11.2014 - 06.2021

Senior CAE Engineer

Honda R&D Center
11.2014 - 12.2015

CAE Analyst

Satyam Venture Engineering Services
06.2012 - 10.2014

CAE Engineer

International Automotive Components (IAC)
10.2010 - 06.2012

MBA - Marketing Management

Department of Management Sciences (PUMBA)

Bachelor of Engineering - Mechanical Engineering

Kavikulguru Institute Of Technology And Science
Vikas Singh Sawan