ANURAG KUMAR
Troy,MI
Summary
MS in Mechanical Engineering from University of Florida (05/2014) GPA: 3.63. Over 9 years of Engineering experience at multiple OEMS (FCA, Ford, Caterpillar). Full cycle product development experience starting from concept design to production including physical and virtual design & assembly validation & testing.
Overview
10
10
years of professional experience
Work History
Senior Battery Engineer
Stellantis/FCA Canada
01.2022 - Current
- Lead Product design and development for next generation high voltage HV Li-ion battery modules for multiple PHEV & BEV vehicle programs.
- Lead suppliers and cross-functional teams for product design & development, virtual analysis, assembly, testing and production
- Root caused & resolved production issues for battery modules & documented lessons learned
- Analyzed & optimized thermal performance of battery module & battery pack for several drive cycles
- Analyzed several performance characteristics for battery cell and module & pack
- Implemented design changes for packaging, tooling, performance, manufacturing of battery modules & battery packs.
- Root caused and resolved validation issues on battery modules for DV & PV. (including durability, swelling, electrical, mechanical & thermal tests.)
- Revised and improved EOL battery inspection procedures and Specifications reviewed EOL data for battery builds
- Revised DVP&R & DFMEA for battery modules
- Obtained certification in battery pack development, BMS & battery characterization & testing from OKU.
Supplier Operations Engineer
TEC Group (Assignment at Stellantis)
03.2021 - 09.2021
- Lead launch activities for Jeep GW composite liftgate; Performed root cause analysis for product design & quality issues; Lead interim and long-term containment activities for manufacturing plant; Lead PDCA's, 8D & Kaizen projects
- Performed APQP & PPAP activities including SPC, MSA, Control Plan, PDR, DFMEA, PFMEA, DVP&R
- Lead continuous improvement and cost reduction projects.
Product Engineer Body Closures
Modis (Assignment at Ford)
12.2019 - 12.2020
- Constructed strategic & engineering best practice documents for steel & aluminum door sheet metal interfaces within vehicle environment (static, dynamic seals, margin seals, rocker, body side, sensors, wiring grommets, speakers, electronic modules)
- Lead cross functional teams to develop robust & cost-effective wiring route to various door components including hardware, switches, electronics, mirrors, and lighting on front & rear side doors
- Lead advanced product design for aluminum side doors for new vehicle program
- Performed glass drop studies and created modified glass surface proposals to address door packaging concerns in Catia & conducted packaging studies for door hardware (handle, latch, power door mechanisms, electronic modules)
- Designed structures and reinforcements, supported architecture set up for side doors development.
Product Engineer
TEC Group (Assignment at FCA Fiat Chrysler Automobiles)
04.2016 - 12.2019
- Lead design release of exterior trim, molded plastic & stamped metal, functional and non-functional appliques, and other trim parts
- (Shepherded 2021 Jeep Grand Cherokee plastic door appliques from concept through launch)
- Benchmarked competitor's products for product development & constructed engineering build objectives & best practices
- Created concept design proposals including datum scheme, locating strategy, fastening scheme definition, surface finish proposals & created material selection matrixes
- Developed technical statement of requirement/work (SOR/SOW) and performed supplier technical assessments for sourcing
- Lead design reviews, technical reviews, and cross-functional product development engineering meetings.
- Coordinated in development of criteria/requirement sections for A, B &C pillars (NX) and packaging of trim components on side doors.
- Designed products for injection molding & implemented design changes as per tooling feasibility & mold flow simulations.
- Created DFMEA, ICD (Interface control document)/ Boundary diagrams & DVP&R for Appliques; reviewed PFMEA, process flow maps & control plans.
- Performed GD&T (Geometric Dimensioning and Tolerancing) and Tolerance Stack ups (Tolerance Analysis) & coordinated in gauge development, gauge reviews; defined quality control points; reviewed SPC, process capability data for quality improvements.
- Performed physical assembly validation & root caused launch issues.
- Resolved production quality, warranty issues & lead cost reduction projects on several parts on multiple vehicle programs.
Design Release of Body Closures & Mechanisms
TEC Group
04.2016 - 01.2018
- Design Release of Door systems, Door Hinges & Door Check mechanisms
- Benchmarked competitor's product for developing new product;revised engineering best practices, DVP&R and DFMEA; established product functional & HMI requirements.
- Conducted swing studies and packaging studies to set up door open angles, door check detent angles, door cut lines; coordinated in development of A & B Pillar sections and closures design development.
- Coordinated component & system level DVP&R testing on door hinges and door checks; Root caused and solved product validation and launch issues.
- Developed Statement of Requirement (SOR/SOW) and performed supplier assessment; lead design reviews & cross-functional product development meetings for door mechanisms.
- Coordinated door system-level validation testing on 2018 Jeep compass side doors, root caused and solved validation failures; coordinated with CAE for side doors product development, validation testing &implemented sheet metal design changes to solve validation issues.
- Reviewed system and component level CMM, gauge & scan data to root cause quality and warranty issues for doors and mechanisms.
- Executed 1.5 million USD/year cost reduction project successfully by elimination stiffening patches on side doors.
Mechanical Design Engineer
Belcan (Assignment at Caterpillar)
06.2014 - 01.2016
- Designed sheet metal brackets for supporting engine oil lines, water lines and wiring harnesses; Implemented design changes and cost reduction ideas; Lead design reviews, created BOM, conducted GD&T, revised DFMEA and DVP&R; reviewed PFME, process flow maps & control plans
- Completed green belt training in DMAIC six sigma
- Worked on Hypermesh and Abaqus for FEA of Engine components (fuel injectors, relief valves, manifolds, and cylinder head).
Education
Master of Science - Mechanical Engineering
University of Florida
Gainesville, FLBachelor of Engineering - Mechanical Engineering
Sathyabama University
Tamil Nadu, IndiaSkills
- CAD: Teamcenter, Vis-Mock Up, Catia, NX, Solidworks, CREO
- Soft Skills: Microsoft Office, Excel, Power point, G-Suite
- CAE/FEA/CFD Software: Hypermesh, ABAQUS, ANSYS
- Programming: C, C, MATLAB
- Manufacturing Process & Materials: Injection molding, Stamping, Steam molding, Prototyping; Plastic, Steel, Aluminum, Molded & extruded rubber, adhesive tapes & NVH/BSR foams
- Engineering Skills: Product design & development of structures & mechanisms, GD&T, Tolerance Stack ups, Packaging, Design reviews, FEA, Validation Testing, DFA, DFM, DVP&R, DFMEA/PFMEA, DFM, DFA, DFSS, FMVSS, SOW, Technical reviews, RFQ, Kinematics, Dynamics, Red-X
- Quality Skills: APQP, Control plan, SPC, MSA, PPAP, Root cause analysis, 5 whys, Fish bone, 8D, Kaizen, Warranty issue resolution, Continuous improvement, Cost reduction, VA/VE
- Certification/Training: Battery Pack Design, Battery Performance, Battery management system (BMS)
Accomplishments
- DRE for next gen PHEV & BEV battery module programs
- Shepherded 2021 Jeep Grand Cherokee plastic door appliques from concept through launch
- Supported Launch of 2022 Jeep GW composite lift-gate
Timeline
Senior Battery Engineer
Stellantis/FCA Canada
01.2022 - Current
Supplier Operations Engineer
TEC Group (Assignment at Stellantis)
03.2021 - 09.2021
Product Engineer Body Closures
Modis (Assignment at Ford)
12.2019 - 12.2020
Design Release of Body Closures & Mechanisms
TEC Group
04.2016 - 01.2018
Product Engineer
TEC Group (Assignment at FCA Fiat Chrysler Automobiles)
04.2016 - 12.2019
Mechanical Design Engineer
Belcan (Assignment at Caterpillar)
06.2014 - 01.2016
Master of Science - Mechanical Engineering
University of Florida
Bachelor of Engineering - Mechanical Engineering
Sathyabama University
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