Uday Kiran

Experience

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  Thermax Limited

  Oct 2021 - Apr 2023

  Mechanical Engineer

  ● Designed automotive clutch plates using SolidWorks and ANSYS, increasing wear resistance by 25% through stress analysis of friction surfaces and GD&T for spline tooth specifications. ● Conducted structural analysis on steel shelving brackets, reducing material costs by 10% by optimizing wall thickness and fillet radii under load conditions per engineering standards. ● Programmed Computer-Aided Manufacturing (CAM) toolpaths for milling aluminum heat sink extrusions, shortening fin profile machining time by 15% with CNC spindle speed adjustments. ● Validated assembly processes for solenoid valve components, achieving 95% first-pass yield on plunger seals and coil windings through torque checks and pressure testing methods. ● Created Bills of Materials (BOMs) and technical drawings for HVAC duct fittings, reducing elbow and flange fabrication errors by 12% with accurate weld joint specifications. ● Supported Corrective and Preventive Action (CAPA) for injection-molded plastic gears, decreasing rework rates by 18% by modifying mold gate locations and cooling parameters. ● Analyzed fastener torque data for motor mount assemblies with Excel and SAP ERP integration, saving 100+ labor hours by identifying and correcting bolt tightening inconsistencies. ● Reviewed centrifugal pump casing designs, ensuring 100% compliance with inlet/outlet port tolerances and impeller clearance requirements using CMM measurements. Show less

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  Caterpillar Inc.

  Aug 2024 - now

  Manufacturing Quality Engineer

  ● Developed Statistical Process Control (SPC) systems for automotive suspension assemblies, reducing dimensional variability in coil spring tolerances by 15% using Minitab for statistical analysis and control charting techniques.● Performed RCA, FMEA on electronic circuit boards, resolving solder joint fatigue issues and improving reliability by 20% through soldering temperature and time adjustments. ● Led ISO 9001 and AS9100 quality audits for hydraulic pump production, achieving 98% compliance by refining in- process inspections of seals, pistons, and O-ring groove dimensions using CMM and GD&T principles. ● Utilized Six Sigma DMAIC methodology to optimize gearbox assembly processes, shortening cycle time by 12% and eliminating gear tooth profile errors, saving $150K annually through machining precision enhancements. ● Tracked and validated process capability indices (Cp, Cpk) for precision-machined shafts, ensuring bearing fit tolerances exceeded 1.33 using detailed measurement studies and metrology tools. ● Applied lean manufacturing and Just-In-Time (JIT) techniques to lithium-ion battery pack production, reducing electrode stacking defects by 18% through automation alignment and material flow improvements. ● Analyzed weld penetration quality on chassis frame subassemblies with Power BI and SAP ERP data, increasing first-pass yield by 10% by adjusting welding parameters and monitoring defect trends. ● Trained 25+ operators on Design of Experiments (DOE) and quality tools for injection-molded thermoplastic housings, cutting warpage and surface imperfections by 22% via mold temperature. Show less