DEVNATH VAIJA RAJARAM
Summary
- 15+ years of experience in Automotive Interior Trims (Door Trims, Pillar trims, IP & Floor console) design based on DFM (Design for Manufacturing), Assembly and Serviceability (DFMAS).
- Strong knowledge and experience in Plastics Product development and manufacturing processes.
- Proficient in Design Failure Mode Effect Analysis (DFMEA), Design Validation plan and Report (DVPR).
- Efficient at multitasking and competent when dealing with challenges.
- Motivated, eager to learn and hard working.
- Exceptional communication and presentation skills and ability to collaborate on projects.
- Ability to adapt multicultural environments.
Overview
17
17
years of professional experience
Work History
Lead Engineer
Nikola Motor
12.2023 - Current
- Lead all engineering efforts, managing styling, non-styling & Seating parts from start to end, inception to production launch, ensuring alignment with project objectives
- Develop and maintain Design Verification Plans and Reports (DVP&Rs) to validate functional, dimensional, aesthetic, and durability requirements of new plastic components and assemblies
- Refine designs for functionality and aesthetics while providing detailed guidelines for serviceability, retrofit, and installation of thermoplastic components
- Support manufacturing facilities in resolving quality issues and ensuring smooth launches, collaborate with suppliers to validate gauges for quality standards, and draft SOWs with technical specifications and deliverables for supplier onboarding
- Oversee the development of next-generation cab, including layout designs, Bill of Materials (BOM) creation, packaging studies, and feasibility analysis to ensure system-level integration and manufacturability
- Conduct Design reviews to address vehicle-level issues, implement containment strategies, and track progress using Jira for resolution
- Define and manage keep-out zones to ensure compliance with vehicle-level static and dynamic clash and clearance requirements
- Lead the launch of plastic components while evaluating mass reduction opportunities to balance cost, timing, and technical impacts for improved efficiency
- Applying GD&T and Tolerance Stack up on CAD data system and component level
- Responsible for CAD deliverables both 3D & 2D
- Ensure alignment of BOM releases across various Product Lifecycle Management (PLM) systems to maintain consistency and compatibility
- Effectively manage the engineering budget, covering design activities, development efforts, and investments in new tools and technologies
Product Engineer
eShocan LLC
02.2021 - 11.2023
- Complete Ownership on Vehicle interior trim parts for a Pick-up truck (all categories) & Passenger segments like Underseat storage, A, B & C pillar, HV covers, IP parts (Side panel and driver side undercover, Cluster parts & Center console parts)
- Reviewing the Styling surface, provide feedback & propose class-A surface based on manufacturing feasibility
- Providing engineering directions to team on design execution using CATIA V5 adhering to customer's design requirements
- Working with cross functional teams and maintain project reports, and design executions
- Address open issues and maintain the live documents, resolve using systematic approach in addressing the root cause
- Applying GD&T and Tolerance Stack up on CAD data system and component level
- Responsible for CAD deliverables both 3D & 2D
- Trial build support for CV build, 1A build to understand Design vs execution on DFA & DFS perspective
- Responsible to address development and quality related issues
- Communicate with Program owners to resolve any questions / concerns & progress & Review update to confirm accuracy of updates and sign off
Lead Engineer-Design
Detroit Engineered Products
09.2020 - 02.2021
- Company Overview: (Client: SA Automotive)
- Team Lead in Design Execution on Door trim for a startup Battery operated vehicle
- Reviewing the Styling surface from customers, provide feedback & propose class-A surface based on manufacturing feasibility
- Benchmarked all competitor pick-up trucks door trims in understanding the packaging conditions, manufacturing process followed, fit & finish and trends followed
- Providing engineering directions to team on design execution using CATIA V5 adhering to customer's design requirements
- Proposing Class-A surface part split based on manufacturing, assembly feasibility
- Working with cross functional teams and maintain project reports, DFMEA and related documents
- Address open issues and maintain the live documents, resolve using systematic approach in addressing the root cause
- Applying GD&T and Tolerance Stack up on CAD data system and component level
- Co-ordination of Customer Design activity with offshore engineering team
- Responsible for CAD deliverables both 3D & 2D
- Responsible to address development and quality related issues
- Communicate with Product owners to resolve any questions / concerns & progress
- Review updates with Customer to confirm accuracy of updates and sign off
- (Client: SA Automotive)
Project Engineer-Design
Easi LLC
01.2018 - 08.2020
- Company Overview: (Clients: Magna & Toyota Boshoku)
- Execution of interior plastics on instrument panel, Glove box development, Overhead storage unit, seating systems & sheet metal design for passenger and Semi truck programs
- Participated on benchmarking on the latest design on market to understand the trends and designs
- Engineering directions in CAD using CATIA V5 with constant interaction with customers based on the DFMA feasibilities and customer requirements
- Co-ordination of Customer Design activity with offshore engineering team
- Quality check on the offshore deliverable
- Supported on updating customer documents such as DFMEA, update design based on the failure reports and suggested design change on manufacturing feasibility
- Applied GD&T on part level cad data and performed Stack up analysis for assembly design
- Responsible for CAD deliverables both 3D & 2D, support CAE team on analysis
- Responsible to address development and quality related issues
- Communicate with Product owners to resolve any questions / concerns & progress
- Review updates with Customer to confirm accuracy of updates and sign off
- (Clients: Magna & Toyota Boshoku)
Project Engineer-FEDE Migration activity
Easi LLC
02.2016 - 12.2017
- Company Overview: (Work location: Ford Motor Company)
- Lean Failure Mode Avoidance (DFMEA) documents
- Verifying Requirements and Evaluation Methods and correction on projects
- Maintaining data by tagging data to facilitate migration
- Supervised and worked with Process Methods Tools & Information team for continual improvement
- Coordinated with Process Methods Tools & Information, Quality Office, IT, and Core engineers to determine task feasibility
- FMA data set review
- Supported on Six Sigma in reducing the process down time on the migration process followed and reduction of 66% of the time from regular time consumed and presented in GBS-FORD Best fair
- Review updates with system document owner and Process Methods Tools & Information engineer to confirm accuracy of updates
- (Work location: Ford Motor Company)
Design Engineer-On Going Product Development - DVD
Easi LLC
06.2014 - 01.2016
- Company Overview: (Work location: Ford Motor Company)
- Design and development of Instrument panel, Interior (Hard & Sort Trim), Floor consoles, duct components for various vehicle programs at FORD, Centre console for B515 program and achieved in parts reduction and worked on integrating all the parts in single tool
- Performing a Data Integrity Check, master section development, interaction with studio team, die lock solving/Draft, attachment creation, analysis to avoid discrepancy in data and rectify faults before proceeding with the changes requested by the Engineer
- Updating the CAD & Drawing as per the Ford Engineering standards and implementing GD&T
- Updating designing process in Worldwide Engineering Release System (WERS) and in Global trackers
- (Work location: Ford Motor Company)
Design Engineer - NGC CAB, Product design Development
Unit Force Technologies
09.2012 - 06.2014
- Company Overview: (Client: Ashok Leyland, Chennai)
- Plastic parts (styling & non styling parts) of NGC-Next Generation CAB and MVP
- Executed plans and workflow of Instrument panel, Hard trim, Upper console, HVAC components, Floor carpet, Door Seal
- Responsible for reducing assembly time using DFMA methodology for Wiper and reduced 33 seconds on assembly line
- Issues resolution for DV & PV build vehicle failures from testing standpoint
- Design coordination of Soft trim parts while ensuring, ergonomics, engineering feasibility & provide Fit and Finish standards to assure quality conformance
- Support on Core Tools like PFMEA, APQP
- FRR (Failure Resolution Report) generation based on the NCR (Non-Conformance Report) raised from testing conducted
- Rectifying the design failures issues raised at ORT (On Road Trail) for the pilot vehicles before product Launch
- Resolving by following 8D process from the CFRs raised PPAP documentation support for project launches, used ENOVIA
- (Client: Ashok Leyland, Chennai)
Design Engineer
Edu Tech NTTF INDIA PVT.LTD
10.2007 - 07.2010
- Process planning and development, Project Planning and Execution as per the plan without deviating from timeline
- Product and Process validation - Building prototype and validate products for its aesthetics, engineering aspects and performance of the product
- Developing products by reverse engineering, Prototypes, Part validation at the customers end- physical testing, interpret & generate test result
- Initiate meeting with team and update project tracking, update team and the customer on progress of the development
Education
M.S. - Product Design
M.S. Ramaiah School of Advanced Studies
05-2012
Post-Diploma - Tool Design
Nettur Technical Training Foundation (NTTF)
09-2007
Diploma - Tool & Die Making
PMC Tech
05-2006
Skills
- Product Design and Development
- Problem Solving
- Automotive Plastics Design
- Quality Assurance/Check
- Product Reengineering/Redesign
- Production Release
- Mentoring & Training
- Team Management
- 3DX/CATIA V5
- DFMEA
- Project management
- Why analysis
- NX
- DFMA&S
- Root cause analysis
- PLM-Team Center
- SolidWorks
- PPAP
- NCR
- Enovia
- AutoCAD
- PFMEA
- 8D
- Jira
- MS Office
- APQP
- DVPR
- Boundary Diagram creation
- Digital Sculpture
- Build Requirements
- Process Methods Tools
- DV
- PV
- On Road Trial testing
Accomplishments
- Excellence Award in bringing down time to 1/3 of regular process in FEDE migration
- Ford SPOT recognition Award for quick turnaround and planning on execution of FEDE migration process
- Ford SPOT Recognition Award for quick turnaround for execution on Quarter Trim Part
- GBS-FORD best fair for execution of less BOM time in 3D CAD
- Awarded Merit for reducing cost on wiper parts, reducing time on assembly line using DFMA methodology at Ashok Leland
Timeline
Lead Engineer
Nikola Motor
12.2023 - Current
Product Engineer
eShocan LLC
02.2021 - 11.2023
Lead Engineer-Design
Detroit Engineered Products
09.2020 - 02.2021
Project Engineer-Design
Easi LLC
01.2018 - 08.2020
Project Engineer-FEDE Migration activity
Easi LLC
02.2016 - 12.2017
Design Engineer-On Going Product Development - DVD
Easi LLC
06.2014 - 01.2016
Design Engineer - NGC CAB, Product design Development
Unit Force Technologies
09.2012 - 06.2014
Design Engineer
Edu Tech NTTF INDIA PVT.LTD
10.2007 - 07.2010
M.S. - Product Design
M.S. Ramaiah School of Advanced Studies
Post-Diploma - Tool Design
Nettur Technical Training Foundation (NTTF)
Diploma - Tool & Die Making
PMC Tech
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