Ilayaraja Moorthy

Experience

• 

  AFCONS Infrastructure Limited

  Jun 2013 - Jan 2014

  Graduate Trainee Engineer

  Maintenance Engineer of Heavy commercial Vehicle ( Excavators, Motor Grader, Road Trucks ) & Generators.Ensure the maximum availability of the heavy vehicles.Maintaining record of vehicle data in SAP.

• 

  Central Institute of Plastics Engineering and Technology (CIPET) - Chennai

  Feb 2014 - Jun 2014

  IES Trainee and Intern

  • Trained for aerospace and automobile plastic product development with CAD/CAM/CAE.• Completed an academic project titled as “Design Optimization of Student Formula One Car Upright using Hypermesh”.• Trained for finite element pre-processing with HYPERMESH and practised engineering problems related to thermal, structural and injection molding domains in FE solvers ANSYS WORKBENCH and MOLDFLOW.

• 

  HCL Technologies

  Jun 2014 - Jun 2016

  Product Design Engineer

  Project 1 Client : Leading medical device manufacturer of Men’s-Health Medical devices, based in USGenerating concept for test methods followed by designing robust and cost effective test fixtures, in added to that detailing fabrication & assembly drawings • Conducting test as per the ASTM Standard• Reverse engineering - Develop working drawings from descriptions/existing physical models.• Drafting molds as per the ASME/ANSI Standards. • Revise and update CAD drawings as required• On considering DFMA, assisting in team design reviews in order to evaluate design concepts and make recommendations. • Assisting team in applying GD&T to the drawings • Maintaining engineering documentation including 3D Modeling, 2D drawing and Assembly instruction via PLM Agile.• Interact with client, as necessary to obtain critical design information necessary to complete project within intended time frame.Project 2 Client : Leading Telecom device manufacturer, based in US• Drive Design for Manufacturing/Assembly (DFM/DFA) and Design for Cost (DFC) disciplines with the goal of reducing design complexity and increasing product quality • Developing engineering design concepts for components and electromechanical assemblies• Perform simple analytical modeling, simulation and analysis at parts /sub system and product levels• Coordinate with suppliers/vendors on parts/sub systems/ systems manufacturing qualification and documentation• Perform tolerance stack up calculations and use Geometric Dimensioning and Tolerance.• Building cost breakdown sheet across different commodities like castings, sheet metal, machined parts, plastics, rubbers, fasteners, burn to shape (laser, plasma cutting), forgings and extrusions. Show less

• 

  Valeo

  Jun 2016 - now

  • Lead DFMEA study & Complete technology risk assessments of products• Identify special product characteristics using Design FMEA• Ensuring consistency between product D-FMEA and P-FMEAs and FMEA interfaces to the customer• Perform Newness level assessment & DRBFM when changes are made to existing design• To ensure regulatory compliance in product & assess the risk involved.• Documentation and archiving FMEAs using FMEA management tool• Creation of reusable FMEA modules for global engineering team• Preparing and handling of documentations related to Functional Safety (ISO 26262) Show less • Worked in advanced projects on e-machine i.e. Integrated starter generator/Gear motor generator (AC induction motor, PMSM) ranging from 4KW to 25KW.• Designing of Inverter/Control module, integrating electronic hardware components with the system.• Work closely with global product management to design/redesign e-machine products related to quality improvements or enhancements on existing products.• Managing Client RFQ & Feasibility study, Packaging of e-machine in powertrain of vehicle.• Adapting Valeo e-machine to customer engine environment & ensure proper clearance.• Manage Tolerance stack-up, Creepage & Clearance in CAD activity.• Knowledge in part design, datum schemes, GD&T and design for manufacture.• Preparation of 3D/2D of brackets, stator, rotor and parts for various e-machine configurations.• Ensure mechanical strength of the part to qualify mechanical and thermal simulation.• Understand the risk thru DFMEA activities & Coordinate with cross-functional teams to have mitigate plan.• Ability to effectively work with cross-functional stakeholders to ensure the design meets their expectations and needs• Maintaining engineering documentation including 3D Modeling, 2D drawing and Assembly instruction via PLM Target. Show less

  • Team Lead - DFMEA

    Jan 2024 - now

  • Senior D-FMEA Engineer

    Apr 2021 - May 2024

  • Design Engineer

    Jun 2016 - Apr 2021