Deepak Thankappan
Livonia ,MI
Summary
Highly successful career contributing extensively to all phases of product development cycle. 16+ years of experience in product development and project management roles. Extensive experience of working on agricultural, construction and off-highway equipment. Experienced in the design of complex castings, gears, sheet metal parts, hydraulics tubes, hoses, engine components, forging and plastic parts. In-depth expertise in performing all aspects of new product design and development process, as well as contributing extensively to enhancement of existing products. Record of high satisfaction levels in engaging with customers and partnering with engineers to acquire and implement product requirements and specifications. Respected for leadership savvy in delivering expert guidance and coaching to on- and off-shore teams. Adept in DFMEA, PPAP, DVP&R and additional processes. Good communications skills, project management skills, proven ability to work and collaborate with cross-functional, diverse and global teams.
Overview
17
17
years of professional experience
1
1
Certification
Work History
Tractor Product Engineer (BEV)
CNH Industrial
04.2023 - Current
- Develop design, layout and drawing in support of electrification of agriculture tractor product line
- Design responsible for tractor CAB, hood, and chassis to allocate vehicle system space claim to sub-system teams
- Collaborate with sub-system teams to integrate component and sub-system design into vehicle master model including tolerance stack analysis
- Create test request and shop work order to support design development and quality verification activity
- Apply appropriate engineering techniques and considerations of manufacturing processes and technology to produce innovative and efficient design solutions considering applicable safety and environmental regulation and standards
- Developed and implemented process improvements to reduce costs and increase efficiency in industrial production.
- Communicated with vendors and key suppliers to select project materials and meet customer needs.
Product Engineer
JLG Industrial
04.2019 - 04.2023
- Company Overview: Deputed by Tata Technologies
- Product engineer responsible for design and development of components, mechanical systems & sub-systems in off highway access equipment to meet design targets established (ANSI B56.6 and ANSI A92/EN 280) in NPI and CPI programs
- Responsible for making design recommendations, and providing direction to the engineering teams, and applications cross functional leaders based on sound engineering principles, practices, and judgment
- Facilitated technical design review and DFMEA reviews with team leaders and cross functional mangers
- Working knowledge of Design of Experiments (DOE), Failure Mode Effect Analysis (FMEA), Root Cause-Corrective Action (RCCA), 8D & 5-Whys Problem solving
- Collaborated with FEA analyst and managed virtual validation task, inclusive of analysis procedures and acceptance criteria for parts, assemblies, and system keys for various NPI and CPI projects
- Drafted testing and verification of new products, as well as prototypes and existing production parts
- Generate cost savings ideas through various VAVE activities: e.g supplier/in house workshops and benchmarking activities
- Assess idea feasibility with X-functional team from a technical and financial prospective on a global basis
- Prepare presentation to support business decision and get management approval
- Track closely the detailed status of ideas implementation (test release, supplier PPAP, customer release), resolve issues to keep timing on track and escalate roadblocks on a timely manner that cannot be solved at the project team level
- Monitor closely savings forecast towards target and propose reaction plan if gap exists
- Collaborate with technical writers and drawing checkers, to create, manage and release ECO’s following the engineering release process using PLM tools
- Deputed by Tata Technologies
- Key Projects: VinFast VF e33/e34 Chassis design (Suspension/sub frames & Brakes), New 6042, 6034, 8042 and 12054 Telehandler component design, Boom Platform support redesign for all boom models
Project Manager
CNH Industrial
02.2018 - 04.2019
- Company Overview: Deputed by Caresoft Global
- Primary role to manage engineering checking, detailing, and releasing team to provide engineering drawing and change notice quality
- To check design layout/3D models and engineering drawing that graphically represent design form, fit and function of moderate to complex design
- Oversee and lead the implementation of process improvements to ensure project targets are met
- Prepare reports: set KPI targets, monthly reports, quarterly report etc
- Provide training and educational services to all departments when applicable
- Deputed by Caresoft Global
- Key Projects: Drawing checking process improvement, Design modifications to 2050M Dozer front hood and blade
Senior Mechanical Engineer
CNH Industrial
03.2017 - 02.2018
- Company Overview: Deputed by Caresoft Global
- Worked for engineering service team enhancing Process and tools
- Part of Creo mentoring team
- Develops, maintains, and deploys work standards for processes
- Manage and execute process engineering change, and review process to include control over process parameters, process methods, tooling, etc
- Resolved Teamcenter, Creo questions from end users and Integrated Creo util with custom map keys
- Deputed by Caresoft Global
- Planned process improvement from beginning to end, focusing on timelines, budgets and mechanical feasibility.
- Managed multiple projects simultaneously, prioritizing tasks to meet tight deadlines and exceed client expectations.
- Applied mechanical problem solving skills to develop creative solutions for quality products.
- Interpreted blueprints, technical drawings, schematics and computer-generated reports for new product development.
- Tested newly installed systems, closely monitoring functionality and adherence to operating specifications.
- Developed innovative solutions for complex mechanical problems, resulting in improved system performance.
- Improved product reliability by conducting thorough failure analysis investigations and implementing corrective actions.
- Conducted root cause analyses for recurring issues, leading to long-term solutions that prevented future occurrences.
- Enhanced product efficiency by redesigning mechanical components and optimizing manufacturing processes.
Senior Mechanical Engineer
CNH Industrial
01.2015 - 03.2017
- Company Overview: Deputed by Caresoft Global
- Reverse engineered AG products for sourcing to new supplier
- Created new drawings for parts, complying with CNH standards and manufacturing specifications
- Expertly fulfil supplier, buyer, and field-warranty engineering action requests (EAR)
- Analyze manufacturing deviations and evaluate risks to disposition affected product
- Skillfully conduct bearing rationalization, resulting in elimination of duplicate/similar bearing part numbers; updated kits to reflect changes
- Deliver expert contributions to project entailing development of new 3D models and 2D drawings
- Deputed by Caresoft Global
- Key Projects: Reverse engineered combine header parts
- Increased customer satisfaction ratings through proactive communication during all stages of project development.
- Identified areas of potential risk during project planning phases, implementing mitigation strategies to minimize negative impacts.
Design Engineer
CNH Industrial
09.2011 - 12.2014
- Company Overview: Deputed by Caresoft Global
- Involved with TLB current product management group for CAB design
- Researched, designed and implemented engineering changes for current product management and cost reduction projects for TLB and Dozer products
- Drafted testing and verification of new products, as well as prototypes and existing production parts
- Worked with CPM team to Performed Design failure mode and effects analysis (DFMEA) and documented test results
- Key contributor in designing structural components, injection molded parts, fabricated design, machined components, non-metallic CAB interiors while fulfilling design and product design
- Responsible for developing, analyzing, and documenting cost information for existing and new product development, design and cost improvement, maintenance, make vs
- Buy, and managing product cost to target
- Participated in change review board meetings, collaborating in root cause analysis (RCA), analyzing results of changes and developing solutions for failure and validation requirements
- Provides engineering expertise to aid in the development of annual and long-term business plans
- Analyze and provide solutions for problems which adversely affect quality, productivity, safety, and flexibility
- Create work orders in a timely manner to ensure scheduling and completion are performed in a timely manner
- Modified ATS, Filters, and cooling system component mountings to accommodate the new stage V engine
- Concept generation, Stack ups, brainstorming
- Drawing creation with geometric dimensioning and tolerancing (GD&T)
- Deputed by Caresoft Global
- Key Projects: Redesigned Side shift carriage for 570ST TLB and new Cab design for 851EX, ATS components Stage V Beta design freeze
Design Engineer
CNH Industrial
08.2010 - 09.2011
- Company Overview: Deputed by Caresoft Global
- Contributed to project entailing quality and reliability testing of Variable Chamber Round Baler components (VCRB)
- Collaborated with Current Product Management (CPM) team to assess and resolve production issues, and to develop new concepts for baler-related parts and combine / hay tools
- Recommends test methods and statistical process control procedures for achieving required levels of product reliability
- Generated and updated Pro/E models and drawings for fit-up/functional tests
- Made verification plans and supervised field-testing efforts
- Work with the test engineering team to develop reliability test and verification plans on systems and subsystems
- Support test data analysis and collaborate with design engineers to resolve issues detected in testing
- Drive thorough root cause investigations and develop effective corrective actions
- Deputed by Caresoft Global
- Key Projects: Resolved Belt slippage issue with New Holland 450 and 460 Round balers
Design Engineer
Caresoft Global PVT LTD
06.2008 - 08.2010
- Performed modeling of complex casting, gears and sheet metal parts in Pro/E
- Contributed to development of new concepts for various combine parts
- Designed pipes and flexible hoses for hydraulic plumbing products and generated schematics for routing pipes and flexible hoses with no interference to environmental parts
- Released change with ECR/ECO process
- Liaised with stakeholders to define and document design requirements.
- Addressed design challenges and evaluated alternative design models to meet project requirements.
- Analyzed and interpreted customer requirements to develop engineering solutions.
Education
Master of Science - Mechanical Engineering (CAD)
SRM University
Chennai India06.2008
Bachelor of Science - Mechanical Engineering
IME
Mumbai India12.2006
Skills
- Design for Six Sigma (DFSS) Methodologies
- DFMEA
- DMAIC Phases
- Quality Improvement Methods
- Design for Manufacturing & Assembly (DFMA)
- GD&T / Universal Detailing Standards Y145
- Root Cause Analysis
- Project Management
- 3D/2D
- VAVE
- DOE
- Hydraulic system design
- Pro/Engineer Creo 4
- CATIA V6
- SolidWorks
- APriori
- MATLAB
- ANSYS 90
- AutoCAD
- MS office
- Teamcenter (TcAE)
- PDM
- Windchill
Accomplishments
- Designed and integrated CAB, hood and enclosures for BEV tractor with accuracy and efficiency.
Certification
- Six Sigma Green Belt, American Society for Quality (ASQ)
- Project Management Professional (PMP), Project Management Institute (PMI)
- Qualified Electrician for HV Systems in Motor Vehicles for Automotive Manufacturers and Suppliers Level 2, TUV SUD
- Certified Fluid power Hydraulic specialist, IFPS
Highlightsofexpertise
- Design for Six Sigma (DFSS) Methodologies
- DFMEA
- DMAIC Phases
- Quality Improvement Methods
- Design for Manufacturing & Assembly (DFMA)
- GD&T / Universal Detailing Standards Y14.5
- Root Cause Analysis
- Project Management
- 3D/2D
- VAVE
- DOE
- Hydraulic system design
Timeline
Tractor Product Engineer (BEV)
CNH Industrial
04.2023 - Current
Product Engineer
JLG Industrial
04.2019 - 04.2023
Project Manager
CNH Industrial
02.2018 - 04.2019
Senior Mechanical Engineer
CNH Industrial
03.2017 - 02.2018
Senior Mechanical Engineer
CNH Industrial
01.2015 - 03.2017
Design Engineer
CNH Industrial
09.2011 - 12.2014
Design Engineer
CNH Industrial
08.2010 - 09.2011
Design Engineer
Caresoft Global PVT LTD
06.2008 - 08.2010
Master of Science - Mechanical Engineering (CAD)
SRM University
Bachelor of Science - Mechanical Engineering
IME
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