Vivek Kumar Contact No.: +91 9975001817, 9146118315

E-Mail: vishik_412@yahoo.com, vishik412@gmail.com

Targeting assignments in FEA /Product Development / Product Validation / Product

Optimisation with an organisation of repute

Location Preference: India (Pune, Bangalore, Delhi & Hyderabad) & Australia

O B J E C T I V E

• To make a significant contribution in an environment that provides opportunity for professional growth &

increasing responsibility.

• Working honestly in a team to bring the best from self & everyone.

P R O F I L E S N A P S H O T

• M.Tech. in Engine Technology with 7 years of experience in FEA, Product Development, Experimental

Mechanics & Validation

• Expertize on Structural (Static & Dynamic), Fatigue, Steady state & Transient analysis.

• Expertize on Structural Optimization of various type of components (Cast, Sheet metal, Forged, Formed).

• Excellent communication, analytical and problem solving skills.

• Expertize in setting up Goals, roadmaps, and execution of set goals for direct reports in the team.

• Experience of project management for team, getting regular updates, discussing updates with global

counterparts & customers, resolving priorities & timeline issues.

• User level experience on experimental test and validation of various components which includes, deciding need

of test, make test plans, design & develop fixture, coordinate test set up and conclude the test results.

• Participated in Design reviews at various design stages (E, D, L & P Phases), and also learnt about completing DR

checklists, creating Pre-read material, presenting in the review, concluding the review with or without coded

issues.

• Six Sigma trained with 2 Six-sigma projects completed. Various tools used e.g. DOE, FTA, Minitab, Concept

generation, Concept selection, Process map, C&E Matrix, CP Tree, P-diagram, DFMEA etc.

• User level experience on Product structure and definitions. Creating Engineering Job Requests and Engineering

Releases.

• Expertize on FIRG & RPS issues, which includes, defining the issue, analyzing the issue, finding out the root cause

and providing solution.

• Coordinating cross-functional activity amongst Design, CFD, FEA & Experimental test/Validations.

• Awareness of product development cycle.

• Expertize in creating training materials and train group of people.

• Expertize in reviewing and mentoring team mates/colleagues for various projects.

• Expertize in working as per Team Based Work System.

C O R E C O M P E T E N C I E S

Product Design & Development Product Validation Product Planning

Product Structure FEA & Technical Knowledge Design Review

Six Sigma Problem Solving Skills Team Management

Project Management

Software Skills: ANSYS Classic, ANSYS Workbench, FE-Safe, Pro-E, Creo, Optistruct, Hypermesh, Genesis,

Mode Frontier, Microsoft tools, Minitab

O R G A N I Z A T I O N A L E X P E R I E N C E

Cummins India Ltd, Pune Feb’ 14-Present

Designation: - Senior Engineer- Applied Mechanics

Key Responsibilities:

• Completed validation tasks for Engine valve cover. Coordinated with various stakeholders for smoothly and

on-time completion of each tests.

• Completed validation tasks for Cylinder head & block. Coordinated with various stakeholders for smoothly

and on-time completion of each tests.

• Lead structural optimization initiatives in the BU. Conducted training sessions, helped to get optimization

projects and supported team to complete the projects with good results.

• Managed 3 employee as my reports. Prepared goals, action plans and feedbacks structure for each of them.

• Participated in many design reviews of various engine components.

• Completed 2 DFSS project. Working on 3rd DFSS project.

• Resolved Cylinder Block failure issue for a new engine program.

• Also, improved very high Cylinder Liner distortion, which was causing blow-by and combustion seal failure.

• Reviewed various projects of the BU team members.

Cummins India Ltd, Pune Nov’ 11 – Jan’14

Designation: - Engineer- Applied Mechanics

Key Responsibilities:

• Worked on Cylinder head, Cylinder block, cylinder liner & head gasket thermal (thermal calibration), static &

Fatigue analysis. Recommendations were provided and geometry optimized for higher PCP.

• Worked on composite oil pan FIRG issue. Prepared and analyzed FTA. Visited local composite oil pan

manufacturer. Identified root cause. Provided geometrical solution. Supported Composite oil pan analysis

process development work.

• Worked on Block bulk head crack FIRG issue. Identified root cause. Worked to improve Last engaged thread

& bulk head for the block.

• Worked on Powertrain analysis for new engine program. Provided geometrical modifications required to

improve bending and twisting modes.

• Worked on analysis of Main Bearing Cap, Liner distortion, Con-rod, Flywheel, flywheel housing analysis.

• Created process and guidelines for exhaust manifold TMF optimization.

Cummins India Ltd, Pune Sep’ 09 – Oct 11

Designation: - Associate Engineer- Applied Mechanics

Key Responsibilities:

• Worked on various Exhaust manifold thermal mechanical fatigue analysis. Worked on various iterations to

improve its life cycle.

• Worked on different engine bracket static, modal, fatigue analysis. Provided recommendations.

• Worked on various Bolted joint analysis.

• Communicated with customers and other stakeholders

• Mentored fresher in their projects related to exhaust manifolds, brackets & bolted joint analysis.

P R O J E C T S

Key Projects Completed:-

1) Composite Oil Pan crack failure investigation (FIRG)-

o Defined problem. Visited Composites material components manufacturers to understand more on

composite components.

o Created FTA (Failure Tree Analysis).

o Analysed FTA probable causes of failure.

o Found out root cause of failure.

o Provided design suggestion to overcome the failure.

o Endurance test performed and no failure found.

2) Block Bulk head crack investigation (FIRG)

o Defined problem.

o Microscopic crack analysis done, and found Fatigue failure and location of start.

o Correlated crack in FEA model and performed iterations to improve design.

o Provided final design to overcome the failure.

o Conducted Block-buster fatigue test which did not show any crack.

3) Block Front and Rear top face crack investigation (FIRG & Six-sigma)

o Defined problem

o Microscopic crack analysis done, and found Fatigue failure and location of start.

o Correlated crack in FEA model and performed iterations to improve design. Completed DOE.

o Provided final design to overcome the failure.

o Conducted Block-buster fatigue test which did not show any crack.

4) Develop process for Exhaust manifold CCI life optimization using Optistruct (Six-sigma)-

o Gathered Voice of stakeholders.

o Thorough study of exhaust manifold, and analysis processes.

o Different approaches for Optimization tried.

o Finalized the optimization approach and validated the Optimization results.

o Created DFMEA for the Optimization process.

5) Completed Experimental and Validation tasks for Cylinder head, Cylinder block and Valve cover

o Finalized & listed experimental & validation tasks required for each components.

o Discussions held with all stakeholders.

o Finalized test plans, equipment required and no. of samples.

o Presented test results to the Management team.

6) Developed process for Bedplate Topography Optimization and used this approach in New Engine

Development

o Defined objective as to improve Bending and Twisting mode frequencies

o Surface geometry model build for Topography optimization and divided part into’ Design’ & ‘Non-design’

parts.

o Genesis is used for Topography optimization.

o Optimization is solved and optimized shapes generated.

o Bedplate is modified according to the optimized shape and it’s validated.

7) Cylinder head, Cylinder block, Cylinder liner Design, analysis and validation support for 3 New HD engine

development-

o Listed out all the tasks required to be completed in given timeline.

o Supported all analysis tasks and provided design suggestions.

o Discussed all input and output data with stakeholders.

o Presented in Design reviews.

A C A D E M I C D E T A I L S

• M.Tech. in Engine Technology from VIT, Vellore & ARAI, Pune in 2014 with a CGPA of 7.8/10

• B.E. in Mechanical Engineering from VIT, Pune in 2009 with 63.6%

• 12th from R.K. College, Madhubani , Bihar State Board, in 2003 with 63%

• 10th from High School, Rajnagar, Bihar State Board, in 2001 with 72%

A C H I E V E M E N T S

• Got MD award for Customer support excellence (Block cracking issue investigation and proposed solution).

• Got MD award for Customer support excellence (Cylinder head project for VPI program).

• Got MD award for Diversity (Organizing cultural event- 10 year celebration of CRTI).

• Got MD award for Corporate responsibility (Scholarship program of Cummins)

• Received 5 Spot awards for 5 different projects.

• Received Appreciation from Jennifer Rumsey (The then executive director-Heavy duty engineering).

• Won 1st position in ROBOTICS competition conducted by D.C.E Delhi in 2007

• Got best manual robot machine award in IIT GUWAHATI in 2008.

• Won runner up in ROBOCON- 09 held in MIT Pune.

H O B B I E S

• Playing Cricket, Badminton, Carom, Cards.

• Watching Movies, Series and listening music.

• Internet surfing & hangout with friends.

E X T R A C U R R I C U L A R A C T I V I T I E S

• Participated in various sports events (Cricket, Badminton, Carom, and Volleyball).

• Active member of Cultural committee and organised several cultural events.

• Participated in several Corporate Responsibility initiatives( Cleaning, plantation, blood donation etc)

P E R S O N A L D E T A I L S

Date of Birth: 01st Dec 1986

Father’s Name: Pawan Kumar Karn

Mother’s Name: Jagadamba Kumari Das

Marital Status: Unmarried

Languages Known: English, Hindi, & Maithili, Marathi

Address: 6, Shiv Vilas Apartment, Balewadi, Pune – 411045

I hereby declare that all the information furnished above is true to the best of my knowledge and belief.

-Vivek Kumar