Baskar Thanusu Email & Phone Number

Collingwood, Ontario, Canada

Chennai, Tamil Nadu, India

- Conceptualized and engineered the Mechanical packaging design for the Integrated Power Cabinet (IPC) specifically for Electrified Large Mining Trucks.- Led 15-member team to successfully execute various projects related to NPD, Proof of concepts and supporting harness components.- Strong technical skills in streamlining projects, coupled with problem-solving skills & decision-making capabilities- Engineered electronic package housing for conditioning monitoring system for PMSM motor with IP67 Protection.- Arranged design review meetings to enhance product quality & perform gap analysis in requirements gathering.- Analyzed design calculation for high voltage bus bar design to reduce design iterations.- Validated interference & interchangeability of assemblies/components through Dimensional & Tolerance analysis.- Provided guidance for Bill of Material (BOM) structure, including parent/child relationships, product/unit effectivity and structuring of BOM to support manufacturing.- Crafted assembly instructions (Build Book) tailored for designs/proto-builds optimized for manufacturing.- Ensuring alignment of project plans and conducting risk analysis to mitigate potential project deliverables.- Review design calculations, stack-up, finite element analysis (FEA), and vibration analysis.

Chennai, Tamil Nadu, India

- Developed End-to-End Product solutions for DC-DC Converter enclosure development.- Conceptualized the enclosure for the Mobility Charger MEC-500 and managed it through to production release- Integrated mechanical packaging solutions for electrical panels in marine applications.- Collaborated with cross-functional teams to develop and implement engineering projects within allocated timeframes and budget constraints.- Brainstorming NPI ideas and creating proof of concepts (POCs) for Motor Control Cabinets (MCC), PLC Panels for marine applications, and re-engineering Electric Panels for Drill machines with multiple configurations.- Carried out bolt sizing calculations using Bolt Joint Analysis to evaluate shear stress and thread engagement.- Acted as a subject matter expert (SME), offering guidance on engineering best practices across the organization throughout different stages of project development cycles.- Provided mentorship to junior engineers to uphold product quality and documented standard operating procedures (SOPs) for work.- Scheduled weekly design review meeting with stakeholders.

Chennai, Tamil Nadu, India

- Restructured workflow process for light Fabrication supporting brackets and eliminated multiple checklist- Expedited the initiation of a new facility engagement with CAT Canada for product development.- Implementing Value Analysis and Value Engineering initiatives to standardize processes and decrease costs.- Initiated a Built-In-Quality process across all products to enhance product design and reduce failures.- Applied service strategy for long lead time items and improvised the inventory management.

East Peoria, Illinois, United States

- Designed enclosures for Variable Frequency Drive (VFD) for Hard Rock cutting machine and MCC cabinet.- Launched facility engagement initiatives for the Power Electronics product lines.- Collaborated with global teams and manufacturing facilities to rationalize the design of components.- Established a process to manage Engineering Change Requests (ECRs) for Power Electronics products.- Composed guidelines to ensure consistency in drawings according to CAT Engineering standards.- Implemented project plans and conducted risk assessments to reduce product release iterations by 12%.- Created work instructions for assembly sequence preparation to construct Variable Frequency Drive (VFD) units.- Adhered to the agreed project timeline set by the Project Management Office (PMO) with a success rate of 87%.

Chennai, Tamil Nadu, India

- Led the 6020B Hydraulic Mining Shovel (HMS) conversion project, overseeing the release of over 4500 drawings within a span of 6 months.- Functioned as a component engineer for harness components including connectors, sensors, switches, and relays.- Designing, documenting and detailing all physical aspects of the product line by generating 3D CAD files and BOM’s.- Prepared a design checklist specifically for light fabrication mount and support brackets.- Led the engineering efforts for designing supporting brackets and sheet metal components for Hydraulic mining Shovel (HMS) and Electric Rope Shovel (ERS) machines.- Achieved high-quality drawings compliant with Caterpillar Standards & Specifications, with a 92% error-free rate.

Chennai, Tamil Nadu, India

- Creating & maintaining product backlog by gathering requirements from the Product Team during release plan.- Organizing and scheduling regular knowledge-sharing sessions to enhance team proficiency in PLM tools and CAT Engineering processes.- Producing high-quality drawings that adhere to Caterpillar Standards & Specifications.- Processed fabrication drawings aligned with manufacturing feasibility and also developing standard documents. - Conducted Root Cause Analysis (RCA) for product quality issues, evaluating design solutions to enhance cost-effectiveness, quality, and efficiency.- Improved the project tracking system to display status matrices, query watch lists, and resource engagement.

Chennai, Tamil Nadu, India

- Design Presentation of Fixture Assembly with Samkrish Machine Tools, Chennai for designing the fixture for the client products for different combinations of jobs- Thermal Analysis for the Casting Component with Samkrish Machine Tools, Chennai for creation of the model in Pro-e Wildfire and later importing it to Ansys basis the parameters defined by clients.- Design of Starter Motor & Starter Generator and Design of Belt Driven Starter with Lucas TVS, Chennai for developing of 3D Model as per the proposed 2D drawings to check design optimization of the components- Generating fabrication drawings based on proto build 3D models to meet manufacturer specifications.- Improved fixture design to achieve optimal bend angle for starter motor conductor wire.- Prepared 3D model for automotive industry to streamline 3D printing/prototyping of starter motor housings.- Improved thermostat model to enhance engine performance by optimizing detection and protection against overheating.