Rohan Bhringol Sharma
Florence,USA
Summary
Mechanical Engineer with 7+experience in Manufacturing and Automotive Sector (R&D Division) with over 3+ experience in logistics and management. Proficiency and experience with thermodynamics, engine’s combustion, emission systems. Hands-on experience with engineering applications such as designing, manufacturing, failure and thermal. Membership of ASME, FABTECH and SAE. Total around 8 years of experience.
Overview
11
11
years of professional experience
1
1
Certification
Work History
Logistics Operations Leader
Cummins Filtration
Walton, USA
12.2021 - Current
- Managed Dock Operations: Oversaw inbound/outbound logistics for containers, truckloads, and LTL shipments, ensuring seamless operations
- Enhanced Safety: Improved skid restacking protocols, increasing dock safety
- Remanufacturing and reverse engineering using our current system
- Supplier Collaboration: Led weekly meetings with suppliers and quality teams, resolving filter-related non-conformances
- MOQ Optimization: Developed suppliers to streamline minimum order quantities, improving dock-to-stock times
- Involved process documentation using WMS system for inventory control and reverse engineering was used based on the transportation and inventory requirements
- Issue Resolution: Addressed supplier-related issues such as shipment damages, incorrect pallet quantities, and poor packaging
- Cross-Training: Trained 15 employees in cross-docking functions, improving warehouse flexibility
- Labor cost was reduced to 20%
- Robotic Project: Led automation efforts to optimize restacking and reduce non-value-added tasks
- Meeting both lean practices and quality control
- VSM Guidelines: Established Value Stream Mapping standards for inbound/outbound operations to meet daily goals
- Maximized Productivity: Achieved 100% productivity in receiving and shipping operations
- Meeting both operations efficiency and customer demands
- ASN Tools: Developed ASN tools to enhance dock work and track KPIs, ensuring customer satisfaction
- Reduced Issues: Cut receiving errors by 65%, achieving 100% on-time delivery
- CAPEX Projects: Led CAPEX initiatives, including safety improvements with reverse palletizers
Mechanical Engineer
MetalTech Industries
Iowa Falls, USA
06.2019 - 11.2021
- Material Development & Optimization: Spearheaded the development of a new high-temperature material for gasket applications, replacing a 30-year-old material
- This innovation increased company sales by 30% and successfully met customer demands for high-quality gasket materials previously considered obsolete
- Applied Solid works for improving the sheet metal design of the gasket
- Testing & Analysis: Conducted Thermogravimetric Analysis (TGA) to evaluate material weight loss under high-temperature conditions
- Updated the Design for Manufacturability (DFM) process and successfully executed the Production Part Approval Process (PPAP)
- Fixture Design: Engineered a custom fixture for ASTM user-defined creep relaxation testing of gaskets, enabling accurate assessment of material performance under high stress and temperature conditions
- Simulation & Modelling: Utilized ANSYS and CONVERGE for comprehensive simulation studies
- These simulations assessed the impact of fluid dynamics on gasket materials under load in high-temperature and high-pressure environments
- Conducted SolidWorks heat studies for heat shield applications, identifying optimal design configurations for improved thermal management
- CFD and Finite Elemental Analysis & Engine Simulation: Performed Computational Fluid Dynamics (CFD) analysis using LES and Spalart-Allmaras models to investigate vortex instability and gas leakage in gaskets
- Applied findings to various engine locations to prevent fume leaks
- Executed simulations using K-epsilon and Spalart-Allmaras models with energy equations to analyse oil flow behaviour and thermal stability at extreme temperatures (up to 3000C)
- Applied Finite Elemental Analysis for finding the effect of pressure with compression as well
- Heat Shield Design & Validation: Identified a heat shield configuration with semi-spherical top surfaces for enhanced heat dissipation
- Validated the design using ANSYS Fluent and CONVERGE, followed by Finite Element Analysis (FEA) for pneumatic testing
- Manufacturing & Quality Assurance: Created detailed testing reports and specification sheets, and led the manufacturing of gaskets for clients including Caterpillar, Cummins, John Deere, New Flyer, and others
- Earned client appreciation for innovative material improvements in engine exhaust gaskets
- Performed CAD/CAM programming to streamline gasket manufacturing processes, ensuring high precision and quality
- Production Management: Led a team of production and machine shop personnel in executing engineering projects, including ASTM test fixture design, fabrication, and material development for metal-reinforced gaskets
- Collaboration & Client Engagement: Collaborated closely with Fortune 50 companies to perform hot sealability tests and thermogravimetric studies for multilayered steel gaskets, providing valuable insights into the effects of coatings and enhancing product reliability
Mechanical Engineer
Pressure Products Inc.
Charleston, USA
11.2018 - 01.2019
- Applied CNC coding to sight glasses of Model B,G and I including designing and FEA analysis using ASME coding
- Performed Quotations and purchase orders for CNC parts and level gauges used by US universities and US govt
- Not requiring ITAR
- Prepared RFQ’s and APQP for analyzing heat points for the gasket in the sight glass especially pressure due to the hydraulic friction
- Conducted design of manufacturability using Mastercam new bearing components in 3d modeling software along with engineering projects based on Director of Engineering (stress analysis of Teflon (supporting material) along with gasket)
- Applied CFD and Finite Elemental Analysis studies using ANSYS Fluent for finding the pressure sensibility of sight glasses at high pressure and high flow rates especially with reactive chambers
- Applied CFD to find the chemical reactions affecting gasket and inner walls of the thermal reactors using high viscosity and high temperature model with chemical reactions codes provided by US govt
- Also added this for improving DFM and DFX analysis
- Managed technicians and machine shop people (around 13) for manufacturing of the sight glass
- Produced shop drawings and the required numerical code for CNC mills and lathes for producing the part with machine and material cost analysis with working knowledge of stainless steel and NACE material
- Maintained regulatory compliance status, corresponding with various agencies
- All parts were OEM
Mechanical Designer
CAD Centre India
Chandigarh, IN
05.2014 - 03.2017
- Prototype Development: Utilized CATIA for the design of prototypes, sheet metal and composites of carbon, aluminium and steel, including mouse, keyboard, CPU with electric slots, and hydraulic systems
- Conducted thermal studies (thermal conductivity) using NX for diffusers at angles of 45˚ and 60˚ with a nozzle diameter of 50 mm, integrating stress-strain characteristics and tool management in CAM with SOP and ECR changes
- HVAC System Design: Designed OEM HVAC system ducts with fracture analysis in SolidWorks, identifying failure at 230 MPa (ultimate strength)
- Documented design and analysis files using PDM, adhering to GD&T evaluations and ECR/SOP guidelines
- 3D Modelling and Analysis: Applied AutoCAD 3D for modelling steel pipes, catalytic converters, and engine blocks
- Conducted design and analysis of heat exchangers using ANSYS Fluent, focusing on failure strength and thermal properties
- Team Leadership: Led a team of 121 engineers over 2.5 years in designing components, resulting in a 30% increase in profits
- Battery Analysis: Drafted lithium-ion battery designs and analysed thermal effects from impact testing using SolidWorks
- Conducted lab visits to observe testing procedures
- Part Diagram Preparation: Created part diagrams for the automotive and manufacturing industries using NX, Creo, SolidWorks, CATIA, AutoCAD, and Inventor, tailored to customer specifications
Mechanical Engineer
CIL CLAAS India
Morinda, IN
05.2015 - 12.2015
- Manufactured header (OEM) top cast (sheet steel) (investment casting) (1500-40 ˚C) with quotation and work instruction after DFM analysis
- Prepared quotation for electronic parts and transmission parts to be used in harvester
- Used DFX files from supplier for lazer cutting
- DFX method was used to implement heat analysis of the design at various flow rates and thin layer boundary conditions for leaks
- Analyzed improvement in material strength to 400 MPa of hydraulic pipes (hot pressure casting and 60 % improvement in grain size and CAM tool management and CAM analysis using MASTERCAM
- (VSM time studies for material) and applied sheet metal studies for frame components
- Managed production workers for work orders and fabrication of the parts
- Assisted engine technicians with management schedules and work plan for them
- Managed VSM studies and imaging studies for reducing process waste and increasing quality of parts especially with SEM studies and thermal imaging studies and management of workers
- Prepared BOM, applied SAP software and process time sheet for VSM process showing average waste time reduction from 100 to 56 hours
- Applied GT Suite for post processing of fluid flow and IMEP and BMEP along with heat energy with crank angle
- Applied virtual thermal modelling tool) on prototypes of new engine block cast and gear box
- (increased the penetration of the droplets of fuel (94-98.23% combustion efficiency) with composite SEM, EDM (electron beam and XRD analysis)
- Applied Finite Elemental Analysis for the study of hydraulic pipes especially when they are impacted with high pressure fluids and aerodynamics
- Applied heat transfer analysis using CFD (ANSYS Fluent) to see effects of forced convection at 90 W/(m2K) for different materials (8 % emission reduction) with PDM file flow (heat & pressure) of all the processes
- Failure reports were documented with PDM
Mechanical Engineer
Mahindra and Mahindra (Swaraj Division)
Mohali, IN
01.2014 - 08.2014
- Performed defect detection using DFM and FMEA and with SEM, EDM (electron beam and XRD analysis) following SOP including ECR
- Performed design modelling of shaft and pulley system (OEM) with work instructions for temperature and material
- Performed simulation study on the heat source of the lithium-ion batteries for regenerative braking system project
- Performed material, manufacturing and heat studies and accurate heat treatment of sheet metal and other composite metals for material selection
- Applied APQP and Six Sigma analysis for injection-molded parts used in the regenerative braking system
- These were all hard rolled parts with supplier error found using IR inspection
- Improved differential threaded design for providing good dynamics and structural balance to the tractor
- Managed the group of 6 people for designing to installation and successful implementation of regenerative braking system
- Applied thermography (ultrasonic) for 30 µm defect for parts produced by using Metal injection molding within VSM time study using six sigma and 8D for material strength after manufacturing
- Performed SEM and EDM studies for micromaterial and material analysis
- Applied GT Power for finding flow rate, efficiency and heat released per degree crank angle
- Applied regenerative braking system for improving efficiency and fuel economy with quotation for parts (OEM)
- Analyzed 6 % efficiency enhancement from (25-30.7) (adding ethanol & CFD tools) after SOP manufacturing & material process
- Applied heat transfer analysis using Finite Elemental Analysis and CFD tools for effects of forced convection at 100 W/(m2K) for two shapes of surfaces including emission reduction after ethanol addition (7 % reduction) SEM, EDM (electron beam & XRD analysis (manufact
- Parts)
Mechanical Engineer
HRTC Automobile Plant
Nurpur, IN
05.2013 - 12.2013
- Manufactured engine block cast using investment casting with carbon fiber composite (5% by weight + increase in power to weight ratio) with DFM analysis with VSM studies using 8D studies
- Tested engine block including PFMEA and design validation and process flow
- FEA analysis of structure having lower tensile strength was performed and these parts were rerolled at different quenching requirements to finalize the design using MIM
- Applied Finite Elemental Analysis on 3-D structural analysis for finding the structural deformity at high loads and vibration for engine block and sheet metal parts
- Procured sheet metal manufacturing equipment and applied assembly line units for optimized manufacturing operations
- Managed production workers, manufacturing technicians, and engine technicians for completion of this project
- DOE for finding exact strength and dimensions including tensile testing of prototypes with SOP and PPAP and ECR change with managing group of 5 people for implementing this plan with directions and work plan
- Designed gear box (OEM) with steel at 1450-10˚C for 12 hours using different gear arrangements for 4% more power
- FMEA was performed for the gear parts not having precision to the absolute tenths
- Performed manufacturing studies for selecting the right material and structural analysis
- Added FEA for finding the structural restraints of the drive shaft and geartrain components especially for rotary motion vibration
- Redesigned cooling system for increasing heat release rate (HRR) to 18 % (More durability) with GT power & Suite analysis
- Applied CFD tool for 7 % efficiency enhancement from (22-30.7) within 8 hours of VSM time with PDM (SEM, EDM and XRD analysis)
- Applied heat transfer model using CFD tools (COMSOL Multiphysics) to see effects of forced convection and conduction at 100 and 10 MW/m2 for diesel engine and gear box heat up which emission reduction to 5 % with GT power & Suite analysis
Education
MS - Mechanical Engineering (Thermal)
Wayne State University
Detroit, MI05.2018
BS - Mechanical Engineering
Punjab Technical University (CGC COE)
Punjab, India04.2015
Skills
- Design Modelling
- Engine Combustion
- Engine Calibration
- Quality Management
- Failure Analysis
- Thermal Analysis
- Manufacturing Processes
- Solidworks
- ANSYS Fluent
- Icepak
- PSpice
- WLM
- CATIA
- GT Power
- SEM
- TMS
- NX
- Converge
- SS CNC
- Oracle
- AutoCAD
- Comsol Multiphysics
- Striker Systems
- SOMS
- TGA
- MasterCAM
- WMS
- Red Prairie
- Creo
- ANSYS Maxwell
- SEM/EDM
- SAP
- PROE
- ANSYS Mechanical
- Autodesk
- Access
- Operational Excellence
- Organizational Development
- Key Performance Indicators
- Safety Management
- Stakeholder Management
- Workforce Planning
- Logistics Management
- Risk Management
- Quality Assurance
- Compliance Management
- Performance monitoring
- Project Management
- Budget Administration and ERP systems
- 2D and 3D modeling
- Design Verification
- Continuous Improvement
- Process Engineering
- Prototype Development
Certification
- GD&T
- CATIA
- YELLOW BELT (SIX SIGMA)
Timeline
Logistics Operations Leader
Cummins Filtration
12.2021 - Current
Mechanical Engineer
MetalTech Industries
06.2019 - 11.2021
Mechanical Engineer
Pressure Products Inc.
11.2018 - 01.2019
Mechanical Engineer
CIL CLAAS India
05.2015 - 12.2015
Mechanical Designer
CAD Centre India
05.2014 - 03.2017
Mechanical Engineer
Mahindra and Mahindra (Swaraj Division)
01.2014 - 08.2014
Mechanical Engineer
HRTC Automobile Plant
05.2013 - 12.2013
MS - Mechanical Engineering (Thermal)
Wayne State University
BS - Mechanical Engineering
Punjab Technical University (CGC COE)
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