•Designed controller for PMSM motor using Space Vector PWM. •Developed control model to achieve regenerative braking.•Implemented selective buck-boost control strategy to control buck-boost converter output voltage for constant cruising operation of vehicle.•Calculated switching power losses in buck-boost converter and high voltage inverter switches.•Achieved 42% Reduction in the power losses by implementing control strategy in power electronics circuit of power converter and high voltage inverter.•Performed the final simulation to analyze behavior of all control models for EPA_City, EPA_hwy and US06 cycles

Gasoline Engine Calibration, Control and Testing •Designed Simulink control models for minimum governor, electronic throttle position, electronic fuel injector and spark timing to control engine speed, air, fuel and spark.•Tested and validated control models using HIL test bench and by calibrating PI controller gain.•Developed engine calibration to achieve engine performance around stoichiometric air to fuel ratio.•Performed verification testing on 4 cylinder,4 stroke gasoline engine.Fundamentals of Functional Safety ISO 26262•Performed Hazard analysis and Risk Assessment for Electronic Throttle Controller.•Developed Safety goals and defined ASIL level.•Derived Functional and Technical Safety Requirements and assigned it to several hardware and software components.•Validated ISO 26262 compliance by performing Stuck throttle and power failure test on Throttle controller.

•Designed bottom frame mounting of hydrodynamic spindle for bearing vibration analyzer to eliminate inherent vibrations, performed necessary strength analysis for frame, developed and released 2D drawing of the frame for final production.•Improved rigidity of twin roller spindles on honing machine by implementing Kaizen and by performing DFMEA to eliminate radial and axial play on spindle. •Optimized Honing machine performance by conducting root cause analysis exercise and by implementing cost effective kaizen for tape pulling mechanism of the machine.•Resolved Bearing inner ring bore customer complaint and quality deviations by applying 8D problem solving tools and formats.•Achieved 4% improvement in Overall Equipment Efficiency of Taper Roller Bearing production channel by conducting Value Stream Mapping (VSM) and eliminating non value-added activities from work stations.•Achieved 2S level (from scratch) on Taper Roller Bearing manufacturing channels by conducting 5S audits.•Trained the work force for 5S.•Supervised manufacturing and assembly operation.