Sai Charan Surya Devara

Experience

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  Force Racing

  Jan 2021 - May 2022

  Design Engineer

  -Developed and analyzed a space frame chassis (AISI 4130), achieving a 12% reduction in mass while maintaining a factor of safety of 2.5.-Engineered drivetrain components and integrated them with suspension systems to optimize the overall vehicle dynamics.-Created and refined the bill of materials (BOM) , ensuring cost-effective material usage and streamlined manufacturing processes.-Collaborated with cross-functional teams to ensure drivetrain, suspension, and chassis subsystems met performance and safety targets.-Utilized CAD and FEA tools to optimize the design, ensuring compliance with safety and performance requirements for motorsport applications. Show less

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  TechnipFMC

  Jul 2022 - Dec 2022

  Associate Engineer, Flow Control Department

  -Developed and analyzed detailed CAD models and technical drawings using Siemens NX and SolidWorks, ensuring accurate mechanical components and systems representations.-Generated part reports and engineering documentation, including Bill of Materials (BOMs) and technical specifications, to support project execution and compliance with industry standards.-Conducted structural and thermal analysis using Finite Element Analysis (FEA) tools to ensure design integrity and optimize performance under various load conditions.-Contributed to Engineering Change Order (ECO) processes by revising CAD drawings and updating technical documentation to reflect design changes accurately. Show less

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  Clemson University International Center for Automotive Research

  Jan 2023 - Jan 2024

  Deep Orange 15- Structures and Interiors Engineer

  - Contributed to the development of an off-road autonomous rescue vehicle sponsored by the US Army.- Focused on structures and interior subsystems, playing a pivotal role in designing the vehicle's chassis.- Developed an innovative litter loading mechanism and mock-up for testing purposes.- Conducted comprehensive analysis tasks, including: - Static impact analysis (front, side, and rear impacts) - Torsional analysis - Recovery load evaluation - Vehicle durability testing through 6-foot drop tests- Performed detailed CAD modeling and simulations to optimize structural integrity and performance.- Implemented design improvements based on testing results and feedback from team members.- Developed and maintained detailed documentation for all design and analysis processes.- Participated in design reviews and provided technical insights to refine project objectives.- Presented findings and progress updates to stakeholders, demonstrating the vehicle's capabilities and performance. Show less

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  Clemson University

  Jan 2024 - May 2024

  Graduate Teaching Assistant

  - Facilitated learning by preparing and delivering engaging presentations, effectively communicating complex subject matter in a clear and comprehensible manner.- Provided one-on-one guidance and tutoring to students, offering personalized assistance to address academic challenges.- Graded assignments, exams, and projects, adhering to established grading criteria and providing constructive feedback to students to support their academic growth.

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  Actalent

  Jan 2024 - now

  Contract | General Motors | Battery Assembly Plant | August 2024-Led assembly and quality assurance for Cadillac Lyriq battery modules, ensuring high performance and reliability.-Utilized the 8D corrective action process, root cause analysis, 5 Whys, and Ishikawa diagrams to improve welding processes, resulting in a 15% increase in First Time Acceptance (FTA) and a 6% increase in First Time Quality (FTQ).-Spearheaded cross-functional teams to implement innovative error-proofing techniques through PFMEA, reducing critical downtime and improving assembly efficiency .-Led APQP and PPAP activities for battery cells across 2+ internal suppliers, managing design reviews, process flows, control plans, process capability analysis, FMEAs, MSA, and capacity analysis.-optimized production output from 300 to 1,000+ modules per shift in 9 months, with an 85% boost in equipment efficiency-Developed TIS, SOPs, and quality instructions; trained and mentored new engineers and operators on the MFA production process, ensuring a highly skilled team on the third shift while maintaining quality and productivity standards.-Gained foundational experience with problem-solving methodologies such as A3 and exposure to IATF16949, ISO 9000 quality methodologies, and statistical process control (SPC). Show less Contract | General Motors | Plant Execution | January 2024- Evaluate and address bottleneck areas to enhance throughput and productivity.- Improve productivity metrics related to equipment uptime, cycle time, and quality to reduce total costs.- Participate in lean manufacturing efforts through the implementation of GM’s Global Manufacturing System.-Executed G-Comply processes, completing all red, yellow, and green tag compliance requirements and successfully handing them over to plant operations.- Implement and train teams on standardized work development.- Foster strong relationships with the Production and Maintenance teams to support daily operations on the production floor.- Provide technical guidance and support during significant downtime events, ensuring swift and effective resolution.- Develop and maintain Process Flow Diagrams, Control Plans, and PFMEAs.- Provide technical support for manufacturing operations to ensure smooth and efficient production processes. Show less

  • Manufacturing Process Engineer

    Aug 2024 - now

  • Execution Launch Process Engineer

    Jan 2024 - Aug 2024