Kevin Desai
Indianapolis,IN
Summary
Engineer specializing in high-volume automotive manufacturing and aerospace system design. Achieved over $300K in annual cost savings through process optimization and quality improvements. Proficient in CNC machining and root cause analysis, leveraging tools to enhance production efficiency.
Overview
1
1
year of professional experience
1
1
Certification
Work History
Production Engineer
Tsuda USA Corp.
Greenfield, USA
09.2025 - Current
- Delivered over $300,000 in annual cost savings through cost-per-unit (CPU) reductions, cycle time improvements, and process optimization across multiple production lines.
- Reduced cycle time by 1.7 seconds (3.4%) on a 50.4-second line, increasing throughput and efficiency.
- Decreased scrap by 5% through tapping process improvements, eliminating recurring customer complaints.
- Increased tool life by up to 3× and improved ~12 tools by 25% on average through programming, chip breaker optimization, and tooling grade optimization.
- Diagnosed and resolved dimensional and process-related issues through root cause analysis (5 Whys, Fishbone).
- Conducted CPK studies, validated gauges, and diagnosed issues with measurement systems to ensure quality and process capability.
- Identified cost drivers and prioritized process improvements by developing CPU and scrap analysis tools.
- Programmed and optimized machining processes, improving stability and consistency.
- Led implementation of process improvements across production teams based on findings from comprehensive analyses.
Education
Bachelor of Science - Aeronautical and Astronautical Engineering
Purdue University
West Lafayette, IN08-2024
Skills
- SolidWorks, CATIA, AutoCAD, and Siemens NX
- G-code and CNC machining
- Abaqus
- Simulink and MATLAB
- 3D modeling and printing
- Prototyping and testing techniques
- Process optimization
- Continuous improvement strategies
- Root cause analysis
- Process risk analysis
- Statistical analysis methods
- GD&T expertise
- Project management
- Metrics tracking
- Workflow streamlining
- Microsoft Office Suite proficiency
- Team collaboration skills
- Effective communication
- Critical thinking abilities
Certification
Six Sigma Professional - Green Belt
Projects
WASoOp Instrument Tech Demo Mission Design January 2024 to May 2024
Aerospace & Spacecraft Design
- Spearheaded the design and execution of detailed test plans, advancing a TRL 6 instrument to TRL 7 by rigorously testing and refining key satellite components.
- Performed calculations and test scenarios to optimize orbital paths, data transmission rates, and passover rates.
- Designed and validated antenna angles for satellite-to-ground communication.
- Led weekly project presentations, supervising cross-functional teams to incorporate stakeholder feedback and refine testing protocols for optimal performance.
- Managed spacecraft attitude dynamics analysis and played an integral role in selecting satellite components,
Human-Tended Experiment Design June 2024 to August 2024
Zero-Gravity Flight Experiments
- Led the design and validation of a 1-g model to simulate fluid behavior to support future zero-g testing phases.
- Oversaw the creation of 3D models and the 3D printing of components, building a functional test model for 1-g experiments.
- Analyzed test data to ensure model accuracy, providing insights that shaped the direction of future research.
- Managed a collaborative effort to refine the model, integrating feedback and theoretical assumptions.
Timeline
Production Engineer
Tsuda USA Corp.
09.2025 - Current
Bachelor of Science - Aeronautical and Astronautical Engineering
Purdue University