Karan Chhajer

Experience

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  NITK Racing

  Mar 2015 - Apr 2018

  NITKRacing is a Formula Student team that takes part in competitions in India and abroad and was ranked the 4th best team in the country according to the 2015 Formula Student rankings. • As a member of the Marketing team at NITKRacing, my responsibilities included acquiring sponsorship and interacting with industry to gain their support.• I led the first crowd funding campaign organized by the team. The campaign was a resounding success, with the team collecting INR 2.2 lakhs.• Served as treasurer for the academic year 2016-2017. Show less

  • Head Of Marketing

    Apr 2017 - Apr 2018

  • Marketing Executive

    Mar 2015 - Apr 2017
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  Hydratight

  May 2015 - Jun 2015

  Mechanical Engineering Intern

  • Training sessions on the working and assembly of flanges and related components, an integral part of pipelines. Practical sessions at Hydratight’s training area as well as site visits, to learn techniques like torqueing and tensioning. Officially certified for the same.• Executed project to transfer Hydratight’s equipment database to Oracle and digitize necessary technical data, to enhance productivity

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  TRAGS

  Jun 2015 - Jun 2015

  Manufacturing Intern

  • Trained on welding techniques like SMAW (Arc), GMAW (MIG), GTAW (TIG) welding and the safety conditions required.• Learnt about Non-Destructive Tests like Hardness Test, Penetrant Test, Magnetic Particle Inspection and Radiographic Test.

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  Technip

  May 2016 - Jun 2016

  Mechanical Engineering Intern

  Collaborated with the mechanical and piping division. Experience with both static and rotating equipment. • Extensive training on pressure vessels, pumps and compressors. Familiarization with Process and Instrumentation Diagrams (P&IDs), piping modelling and material selection. • Opportunity to gain experience with ASME Sec VIII and API 650 standards. Project to design a pressure vessel, using PV Elite.

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  Qatargas

  Jun 2016 - Jul 2016

  Mechanical Engineering Intern

  Assisted the condition monitoring team of the Qatargas Utilities division. Undertook intensive training sessions to understand functioning of an LNG plant and safety guidelines involved in the oil & gas industry.• Established thorough understanding of predictive maintenance techniques like vibration monitoring, borescopy and lube oil analysis. • Collected vibration readings for rotating equipment like pumps. Analyze the data for signs of concern and propose maintenance strategy

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  IET NITK

  Apr 2017 - Apr 2018

  Secretary

  • Organizational Head of the society, consisting of 140 executive members.• Oversaw the annual recruitment procedure of the club. Coordinated between different subsections. Managed the presence of the club on campus. Maintained decorum and discipline.

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  TAL Manufacturing Solutions Limited

  May 2017 - Jun 2017

  Mechanical Engineering Intern

  Member of the assembly division of I-section beams for Boeing planes.• Executed time and motion studies to identify the inefficient processes and reduce cycle time. 12.5% reduction in cycle time.• Implemented kaizens, poka yoke, line balancing and 5S strategies to improve productivity

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  Ammann Apollo

  Jun 2017 - Jul 2017

  Mechanical Engineering Intern

  Evaluated designs for the power train of a soil compactor and validated engine selection. • Developed knowledge of fabrication and manufacturing process of the compactor.

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  Timberline LLC

  May 2019 - Apr 2020

  Engineering Intern

  Redesigning plant layout, material handling and machine sites to improve productivity. Using lean principles to cut production times, by fixture and process flow design. Value Stream Mapping. Assess capital projects feasibility. Leading Kaizens and 5S, writing SOPs and training shop floor. Analyze products for DFMA opportunities.• Increased production volume by 42%, 25%, and 67% in 3 ‘GE’ product lines. Reduced assembly time by 41% in ‘Armstrong’ product line.• Designed custom shipping crates using SolidWorks. Developed manufacturing yields, Bill of Materials and prepared final vendor quotes. Show less

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  North Carolina State University

  Sept 2019 - Dec 2019

  Graduate Student Research Assistant

  Advanced Metal Forming and Tribology Lab• Leading the design (SolidWorks) and implementation of hydrodynamic cavitation setup, to achieve surface texturing of materials.• Create manufacturing drawings, equipment selection for setup and build computational models using ANSYS Fluent to mimic process physics

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  Lear Corporation

  Jul 2020 - Dec 2021

  Engineer II

  Champion automation projects for automotive plant with $80M in revenue, redesign processes and implement condition monitoring systems● Led automation using robotics, automated guided vehicles, and vision systems, for products with >$20M in revenue (Budget of $2.5M). Created project plan, scouted new technologies and managed projected timelines- Completed ROI analysis, layout and capacity modeling, risk analysis and pilot studies. Created project budgets, identified suitable vendors, presented to upper management to secure project funding and managed a cross functional team to complete implementation- Formulated scalable automation frameworks and technology roadmap to help Lear reduce hiring needs- Automated the inspection of products resulting in better product quality and savings of $400K and 5 FTEs annually.- Automated packaging process leading to $100k in savings and cutting single use plastic consumption by 650k sq ft annually● Led team of 10 to enhance and rebuild manufacturing equipment, expanding annual volume by $10M annually● Created engineering solutions for ergonomic and safety enhancements, resulting in zero Lost Time Injury (7,200 operational hours)● Identified alternate method to supply hot water to a process, resulting in $300K in savings and carbon footprint reduction of 7%● Redesigned oiling system and routine to avoid downtime and product loss, resulting is $800K in savings (on annual revenue of $30M) Show less

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  MilliporeSigma

  Dec 2021 - now

  Product Development Engineer II