RAJKUMAR KASARIBADHA
Nashville,TN
Summary
Results-driven Senior Mechanical Engineer with over 10 years of expertise in mechanical design, industrial engineering, and product development. Demonstrated success in delivering cost-saving strategies, continuous improvement initiatives, and innovative equipment designs. Proficient in PLM/PDM systems, 3D/2D CAD tools, and CAE simulation/emulation technologies, facilitating the execution of high-impact technical projects.
Overview
10
10
years of professional experience
Work History
Innovation and Design Engineer
Amazon
12.2021 - Current
- Led the concept design for a $1M complex Automation fulfillment center, leveraging data simulations to enhance logistical operations approach and boost efficiency by 25% compared to previous-generation templates, achieving a $2M annual reduction in operational costs
- Oversaw the complete MHE scope of work for projects totaling $50M in CAPEX, from RFP release to post-launch review
- Responsibilities included proposal evaluations, PO issuance, vendor selection, MHE system design and implementation, detailed engineering reviews, change order management, FAT/SAT, commissioning support, launch readiness, and training for site operations leadership
- Designed pick-to-stow carts in Solidworks and Emulate3D, achieving $70K cost savings per fulfillment while significantly improving package picking efficiency
- Designed internal parcel Singulator, written technical specification and contributed to the global standards team to develop auto-divert-to-aisle technology across NA, Europe, and Japan for Amazon last mile
- Assessed air distribution systems to ensure optimal CFM usage and pressure, resulting in CAPEX savings of approximately $60K per site across 8+ fulfillment centers
- Developed an operations tool that evaluated hourly flow for delivery stations, optimizing mechanical capacity constraints
- This improvement facilitated a 20% increase in package distribution efficiency across various sortation subsystem
- Led the automation design program for all North American elevated delivery stations, performing layout assessments for over 74 sites using AutoCAD to create standardized SOPs and design templates for greenfield and brownfield projects
- Performed, analyzed and designed several material handling systems and subsystems for parcel flow on small scale to large scale automation distribution centers and delivery stations using Emulate-3D and Flex SIM
- Designed, developed and launched global EDSD (Engineering design standard document) for NA, EU and Japan on Mech-lite automation
- Standardized and managed 2D/3D CAD templates using AutoCAD, Solidworks, Inventor and Simulation models using Emulate3D and Flex Sim for component level and delivery station templates, ensuring consistency, standardization and efficiency across projects
- Collaborated with Launch, Startup, Execution, Capital Planning, Ops Design teams, and external vendors to successfully launch over 23 greenfield TNS facilities
Mechanical product Design Engineer
Danfoss power solutions (White drives motors and steering)
03.2018 - 12.2021
- Regional PLM leader to oversee 13 members and manage Siemens PLM Team-center tool for ECM and PPAP process
- Managed design and production of hydraulic motor assemblies, and subassemblies using PTC Creo Windchill and Ansys
- Conducted tolerance stack-up analysis for complex motor assemblies with 2-5 microns limits, reducing internal oil leakage incidents by 30%, resulting in improved assembly reliability and decreased maintenance costs
- Implemented a part-level quality verification process, improving First Pass Yield (FPY) from 73% to 96%, resulting in a significant increase in on-time customer order delivery rates and reducing rework costs by over 30%
- Built strong customer trust and relationship as a problem-solver by collaborating with high-valued clients such as John Deere and Bobcat
- Achieved 95% success rate in validating hydraulic motor mechanical and volumetric efficiencies with thorough technical tolerance analysis, static structural and modal simulations using Ansys
- Coordinated weekly meetings with manufacturing engineers to address ongoing FPY concerns to improve part manufacturing performance at subcomponent and subassembly levels through implementation of standard SOPS and PPAP procedures
- Collaborated with onsite quality engineers to improve and standardize component SOPs, resulting in a 25% reduction in production errors and a 15% increase in workflow efficiency
- Engineered an ergonomic and cost-effective lift system for hydraulic motor testing, reducing manual lifting of approximately 70 lbs by 100%
- Improved safety and efficiency, resulting in a 30% decrease in back injury reports and enhanced workflow productivity
- Developed and implemented a standardized Engineering Change Management (ECM) process across cross-functional teams, improving efficiency by 30% and reducing project turnaround time by 20%, leading to enhanced collaboration and timely delivery of project milestones
- Designed, updated and maintained over 500 standard 2D and 3D drawings using GD&T principles, enhancing design accuracy and compliance
- Defined 15 test standards for extensive product testing on new application hydraulic motors
- Successfully validated 10+ international and local suppliers, on-boarded new vendors, enhancing quality manufacturing processes with lean principles, PFMEA, DFMEA and supplier PPAPs
- Experienced in applying advanced industrial design and manufacturing methods, skilled in material selection from casting to finish product, and proficient in tooling technologies to streamline processes and enhance design functionality with quality SOPs
Design Engineer
Ohio transmission corporation
01.2016 - 03.2018
- Created complex 3D module assemblies in Solidworks, AutoCAD and standardize air compressor module builds and manufacturing drawing package.
- Lead VSM (value stream mapping) process to understand lean fabrication and created standard sheet metal fabrication drawings to eliminate fitment issues in future builds
- Collaborated with metal fabrication vendors to reduce costs by 15% for low-flow HVAC duct projects, resulting in significant savings on material expenses
- Streamlined procurement processes, enhancing overall project efficiency and budget management with VSM(value-stream mapping)
- Evaluated compressor heat at full load, achieving approximately 10% CAPEX savings by recirculation system
- Developed piping and electrical layout standards using SolidWorks routing module, resulting in a 20% reduction in design time and improved accuracy for projects valued at over $50K on piping components
- Designed and launched compressed air projects for GM, GE, DANA as primary customers
Design Engineer Intern
Think path Engineering Services LLC
08.2014 - 11.2014
- Developed prints to re-generate cockpit structural frame 2D CAD for CH-47
- Worked with engineers on engine cowl surface improvements using GSD in CATIA V5
Education
Master of Science - Mechanical Engineering
University of Dayton
Dayton, OH12.2015
Bachelor of Science - Mechanical Engineering
Kakatiya University
India05.2013
Skills
- SIEMENS NX 110, PLM/PDM
- Pro/E Creo - Windchill
- Ansys, CATIA V5, SOLIDWORKS, AutoCAD, DFM, GD&T, Emulate 3D
- Design and development
- Project management
- BOM (bill of materials)
- Risk Assessment and Mitigation
- Prototype Development and Tooling Kickoff
- Vendor Management
Timeline
Innovation and Design Engineer
Amazon
12.2021 - Current
Mechanical product Design Engineer
Danfoss power solutions (White drives motors and steering)
03.2018 - 12.2021
Design Engineer
Ohio transmission corporation
01.2016 - 03.2018
Design Engineer Intern
Think path Engineering Services LLC
08.2014 - 11.2014
Master of Science - Mechanical Engineering
University of Dayton
Bachelor of Science - Mechanical Engineering
Kakatiya University
Similar Profiles
Azure HargroveAzure Hargrove
Process Assistant at AmazonProcess Assistant at Amazon
Shaquille Ameen DentShaquille Ameen Dent
Warehouse Associate at AmazonWarehouse Associate at Amazon
John RobersonJohn Roberson
Area Operations Manager at AmazonArea Operations Manager at Amazon