Malhar Kulkarni

Experience

• 

  TAL Manufacturing Solutions Limited

  Jan 2010 - Jan 2011

  Project Intern

  Design of Stacker and Puzzle type automated car parking systems

• 

  Tata Advanced Systems Ltd

  Oct 2012 - Jul 2013

  Intern

  Worked in the Tooling dept, in TARA aerospace systems, for sheet metal work, designing and assisting in manufacturing of Form block templates, contour templates for inspection of Form blocks and parts. Designed and drafting of T-table for easy loading and unloading of fixtures in CNC machines. Currently working in Tooling Dept of S-92 plant (TASL).

• 

  Datta Tools Pvt. Ltd.

  Jul 2013 - Jan 2016

  Leading a team of engineers in Design department and working to make this department as an independent Profit and Cost centre of the Organization. Undertaking individual design and manufacturing support projects for Fixture design, Relation checking gauges and turn-key projects for various auto mobile and engineering sector multinational customers. Looking after all the design activities and involved in various Fixture designs and manufacturing activities. Experience in design of relation checking gauges, machining fixtures, welding fixtures, assembly solutions and special material handling equipments.

  • Sr. Engg -Design and Development

    May 2015 - Jan 2016

  • Design Engineer

    Jul 2013 - May 2015
• 

  Brembo Brake India Pvt. Ltd.

  Feb 2016 - Apr 2018

  Senior Engineer

  Responsible for design of HMC fixtures, CMM gauges, Assembly fixtures for a high volume production setup.Role includes design, followup with supplier and then proving the fixture for Mass production.

• 

  John Deere ETEC

  May 2018 - now

  - Leading a team of over 10 design engineers to support all tool design deliverables for factory shop floors.- Managing tool fixture design activities for Dubuque and Davenport factories across multiple product lines.- Successfully completed over 40 projects with a total value exceeding $500K, driving significant improvements in productivity and safety.- Developing fixtures and tools using advanced design practices such as generative design and lightweight materials.- Collaborated closely with internal tool rooms and suppliers for fixture manufacturing activities.- Created proactive proposals to increase engagement with various departments within Dubuque and other factories in the US and Brazil.- Mentored new team members and led collaboration projects with suppliers and universities.- Supported EPDP, OFP, FMP, and ISDP projects with close collaboration with other competencies, including capital investment planning and should costing.- Addressed shop floor pain points by collaborating with multi-functional teams, focusing on productivity improvement, SERA reductions, and safety hazard elimination.- Conducted virtual validation of tool designs using Ansys structural simulation and VR setups.- Drove employee engagement activities within the team Show less

  • Lead Engineer - Tool Fixture Design

    Jun 2021 - now

  • Senior Design Engineer

    May 2018 - Jun 2021