Karan Virmani, PENG, PMP

Experience

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  Yamaha Motors

  Jan 2009 - Apr 2009

  Manufacturing Engineering Trainee CO-OP

  Worked on designing gauges and jigs using SolidWorks for fabrication processes,painting process, engine assembly process and vehicle assembly manufacturing process.* Worked with the continuous improvement department to implement six sigma practices* Improved manufacturing processes by reducing physical demand on operators and reducingchangeover times * Worked in shop floor for manufacturing parts like Fuel Tank, Frame, Muffler* Performed hands-on maintenance and repairs on manufacturing plants mechanical andelectrical equipment under supervision Show less

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  University of Waterloo

  Sept 2009 - May 2015

  Mechanical Engineering Student
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  Providence Healthcare

  Jan 2010 - Apr 2010

  Engineering Project Coordinator CO-OP

  Designed, developed and implemented a Microsoft Access based database to help managewheel chair orders and keep an inventory of all the wheelchairs in the hospital.* Designed a database in MS Access and MYSQL to manage the wheel Chair orders and keep aninventory of all the wheelchairs in the facility * Conduct hands on maintenance of various hospital electrical and mechanical equipmentincluding control and low voltage panels, boilers and generators * Research and develop AutoCAD schematics for various automated hospital systemsincluding electrical and mechanical distribution. * Updated MSDS of all the chemicals and equipment in the hospital. Experience in updatingMSDS using Well net * Coordinate various maintenance projects including Cost estimate, materials and serviceprocurement and contractor supervision.* Monitor and trend utilities for the Hospital's energy efficiency program Show less

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  Hybrid Tool Mounting Plate for Schmid Press

  Sept 2011 - Dec 2011

  Precision Resources

  Designed a hybrid tool mounting plate using SolidWorks that can mount tools used in fourdifferent presses Characteristics of the tool mounting plate include: * The ability to mount tools used in four different presses * Compatibility to be mounted on two different Schmid Presses* Meets all requirements suggested by Schmid to ensure safety and quality Installation of a Spot Cooler, Yamaha Motors, Jan. 2009 * Apr. 2009 * Research the best possible way to provide effective cooling to the workers in the paintshop without effecting the painting process* Design the best possible way to install the spot cooler in AutoCAD * Work with contractors and complete the installation of the spot cooler.* Developed the detailed development documentation and user manual of the project Show less

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  Precision Resources

  Sept 2011 - Dec 2011

  Enginerring Project Designer CO-OP

  Precision Resources (Project Engineering Designer) (Sept – Dec 2011)Continuous improvement of manufacturing processes that involve Fine Blanking and Metal StampingDesign and draft of tool components and fixturesSupport and create documentation for APQP and tool quoting activitiesHelp in the quality control process for fine blanked parts by designing fixture for parts to help measure parts using the CMMWork on shop floor as required to support proto-type process development and manufacturing as required Show less

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  Melitron Corporation

  May 2012 - Aug 2012

  Manufacturing Support CO-OP

  Worked as a part of the New Product Introduction Team (NPI) on the prototypedevelopment of sheet metal components for electronic chassis, industrial enclosures, self-service kiosks.* Investigated and presented solutions for problems with sheet metal fabrication processlike welding, bending, cutting, power coating and pad printing* Designed modular fixtures using solidworks for welding, painting and pad printing ofsheet metal components* Reviewed drawings for accuracy, correct materials, proper machining techniques,finishes, hardness and made changes, then submit final copies to engineering staff forapproval.* Collaborated with product engineers and production floor associates to set up assemblyline for self-service kiosks.* Performed six sigma time studies to assist with line balancing to improve productiontime Show less

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  University of Waterloo Mars Rover Team

  Sept 2012 - Feb 2013

  Mechanical Design Team Leader (Student Team)

  Designed a Robotic Arm and Chassis for the Mars Rover Competion using SolidWorks* Performed kinetic calculations on different motion mechanisms within the robot* Designed a differential motor system for the robot.* Fabricated parts for the robot in the student machine shop in waterloo* Gave tutorials on the use of SolidWorks and machining to members of the mechanical team* Assigned different tasks to the members of the mechanical team* Worked with the Electrical and Software teams to integrate different systems Show less

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  Babcock & Wilcox

  Jan 2013 - Apr 2013

  Nuclear Design Engineering CO-OP

  • Assisted the lead engineer in the Nuclear Engineering Department with the thermal and structural design and analysis of pressure vessels, steam generators and heat exchangers in accordance with the ASME Boiler and Vessel Code, Section III, class 1 requirements • Used ANSYS and knowledge of Mechanics of Deformable solids for the linear elastic structural evaluation of components• Used MathCAD to carry out Thermal/Hydraulic calculations on heat exchangers and steam generators• Created engineering calculations by manipulating experimental data and producing a variety of graphs for data presentation Show less

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  Magna International

  Sept 2013 - Dec 2013

  Process Engineering CO-OP

  Designed fixtures using Unigraphics NX and helped with part setup design projectsDeveloped solid 3D CAD models of GM and Chrysler products using Unigraphics NX8 in order to integrate into a robot simulation package.Used Designs of Experiments to analyze effect of fluid flow, shape air, atomization and Kirchhoff’s Voltage on paint qualityConducted product validation trials to understand Transfer Efficiency differences between different paintapplicators and to study different types of defects on painted partsHelped with quoting process for new business.Designed and implemented concepts in order to optimize processes and increase productivityHeavily involved in the technical development of color using a Bell Bell paint application processImplemented Neural Networks using Matlab to analyze data Show less

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  Peerless Custom Rack

  May 2014 - Aug 2014

  Design Engineering CO-OP

  Prototype development of tooling used to hold parts during electroplating and painting processes using 3D CAD Design in Solid WorksImplemented continuous improvement initiatives by investigating and presenting cost saving solutions for problems with metal fabrication process like welding, bending, cutting, punching and assembly.Visited plants specializing in painting and electroplating processes to understand their tooling needs, Participated in internal and customer meetingsWorked on creating quotations and project budgets Preparation of detailed project execution plans/schedulingContact vendors and collect quotations to identify products and strategies to reduce project costs Preparing and maintaining project meeting minutes and open issues listImplementation of Six Sigma and 5S ProjectsWork closely with the business development manager, plant manager and department leads to ensure that the project resource requirements and schedules are being maintained Preparation of Operating Instructions and APQP Documentation Show less

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  Honda of Canada Mfg.

  May 2015 - Jan 2021

  • Coordinate the activities of team members, suppliers/vendors in the execution of projects, ensuring technical and regulatory compliance standards are met.• Work on creation of detailed specifications for automated equipment to ensure deliverable's are well understood at the beginning of the project.• Offered design solutions that effectively solved problems and enhanced project goals. • Develop estimates on cost of equipment. Including estimates on cost of parts, fabrication time and cost of electrical panels. • Report on a monthly basis on cost, quality and delivery status of projects. • Provide direction and support to the field technicians before, during and after installation. Show less Designed all tooling used to handle plastic parts starting from injectionmolding to final assembly to support new model change for 2017 CRV.• Oversaw all aspects of design and development, selected componentsand managed vendors.• Designed 11 different types carts including tooling to hold front and rearbumpers, front and rear lower garnish, instrument panel, material andplastic parts for the instrument panel.• Assisted with design changes on injection mold tooling for bumpers Show less (Hired at Honda under the EDP - Engineering development program, underthis program new engineers at Honda are placed in a host department foran year with a mentor and are then placed in their permanent department)• Worked on die engineering projects to support design changes for 2016Civic launch and 2017 Crv launch.• Made design changes to stamping die’s in Catia using surface modelingand programmed CNC to machine die’s• Designed tooling and jigs using Catia to hold parts. Worked withsuppliers to trial new equipment that needed to be installed on theconveyors to support this project. Ran trials and made improvements tothe equipment.• Performed time studies and designed flow for the process. Worked withproduction team leaders to optimize the process and flow of parts fromstamping department to weld department Show less

  • Sr Project Manager

    Jan 2020 - Jan 2021

  • Engineering Project Lead

    Jan 2018 - Jan 2020

  • Mechanical Designer

    May 2016 - Dec 2017

  • Stamping Die Engineering (Engineering Development Program) at- Stamping Department,

    May 2015 - May 2016
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  Purolator Inc.

  Mar 2021 - Jun 2022

  Regional Engineering Project Manager, Central Canada- Material Handling Equipment

  Lead specification, design, integration, installation and commissioning of automation and Material Handling Equipment across Central Canada, Metro and Greater Ontario.

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  Tesla

  Jun 2022 - May 2024

  Staff Project Engineer, Material Flow Automation

  Lead Automation Projects in the Material Flow Automation Team.Oversaw strategic design of material flow equipment for Austin Giga Texas. This included complete equipment development from identification of needs, concept design, prototyping, and final equipment design.Directed all phases of large projects from need identification, concept generation, specification, mechanical design, testing and installation of equipment including procurement and RFP and RFQ creation. Managed over fifty plus million dollars of Material Handling Automation equipment design, commissioning, installation and SAT. Systems achieved 99% availability during SAT. Prepared business case studies for automation equipment balancing Opex vs Capex. Got a total Capex of over fifty million approved for various Material Flow automation projects needed for launch of Cyber Truck and Model Y production improvements. Collaborated with cross functional teams to drive projects forward and ensure projects successfully meets KPI metrics.Oversaw design and development of warehouse design with a ASRS system with a storage capacity of 50,000 pallets.With an inbound and outbound throughput of 150 pallets an hour.Responsible for defining, improving and demonstrating equipment, subsystem, and system performance criteria. Oversaw estimates on manufacturing costs, time studies, and concept design of tooling and process requirements.Directed a team of over 5 manufacturing engineers leading automation projects. Overall team managed several different project at the same time to deliver exceptional results in a very short period of time. All projects were critical to Model Y line ramp up and Cyber Assembly lines.Projects consisted of Body conveyance equipment, conveyor roller beds, cell manufacturing equipment, ASRS systems, VRC equipment, robotic cells, Power, and Free and EMS systems conveyance systems.Responsible for managing vendors, including obtaining pricing for MHE Systems. Show less

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  Rivian

  Jun 2024 - Nov 2024

  Equipment Design Engineer

  Lead Specification, Design, install and commissioning of Material Flow/ Supply chain equipment including AGV, AMR systems, conveyors, material handling automation cells.