Donald Verghese Jacob Email & Phone Number

Itasca, Illinois, Us

• Led product development from ideation to mass production for Balanced Armature (BA) Receivers, Receivers-In-Connectors (RIC) & Hybrid Earphones.• Designed complex micro sized plastic and metal parts that incorporated both mechanical and electrical components such as rigid and flex PCBs.• Conducted design reviews with a cross-functional team to develop low risk and robust assemblies ensuring all acoustic, electrical and mechanical requirements are met.• Led design activities in several NTI projects that explored functional improvement of BAs such as increase in acoustic output, ability to perform at reflow temperatures and incorporate noise cancelling in Hybrid earphones.• Conducted Linear and Non-Linear FEA Simulations using ANSYS that helped provide initial design guidance towards early prototypes and recommended improvements to existing designs.• Supervised technicians during prototype builds and consulted with manufacturing engineers to ensure selection of robust processes and materials.• Collaborated with Quality & Electroacoustic Engineering as well as Asia-based factories to identify design and process risks, lead DFMEA’s and formulate test plans.• Identified innovative value creation opportunities from both design and process perspectives reducing product cost by 10 to 15%.• Strategized with Product and Program Managers to bring new products to market by working directly with customers and communicated design concepts for improved fit, form & function.• Managed mid to large scale projects, created schedules and collaborated with all cross-functional teams to ensure projects run smoothly.

Itasca, Illinois, Us

• Developed Receiver-In-Connectors (RIC) & Balanced Armature (BA) Drivers for Hearing Aid Devices and True Wireless Earphones using ProE & ANSYS through entire product lifecycle from ideation to mass production.• Managed and coordinated design, FEA, process and reliability activities with cross-functional teams and communicated design concepts with customers for improved fit, form & function.• Strategized with various stakeholders on meeting project timelines and worked with vendors on reduced pricing and quicker turnover by analysing and redirecting activities between vendors and Knowles factories.• Identified value creation opportunities by collaborating with injection molding and metal manufacturing suppliers which improved product margins by 25% and UPH by 10%.• Supervised technicians during prototype builds and consulted with manufacturing engineers to meet customer requirements and deliver samples in a timely manner.• Supported NTI activities with a focus on improving BA performance by 5dB at low frequency and high frequency to deliver high-fidelity sound at a lower cost to the everyday listener.• Conducted FEA Analysis on a connector-socket system to analyse disconnection pull force and recommended steel-safe tooling changes to the supplier which helped achieve customer pull spec requirement with little to no tooling change cost.

Itasca, Illinois, Us

• Responsible for evaluating, initiating, and executing product designs, design changes, and improvements of micro electro-mechanical devices. • Support new product development and contribute to success of complex engineering projects by performing diversified engineering, research, and development. • Research new technologies, product solutions, design, and development of micro electro-mechanical components according to customer specifications. • Perform engineering, research, and development assignments and initiate, evaluate, and document development of new products in accordance with internal procedures and new product development process. • Responsible for the initiation and implementation of a technology roadmap by researching new technologies and materials, initiating and implementing cost reduction activities, as well as, establishing engineering processes that lend itself to proper engineering practices and rapid product development.

Cham, Zug, Ch

• Supported the Mechanical Engineering Organization by conducting thermal-electric analysis of electric meters using ANSYS Workbench Simulation & Matlab to analyze the amount of heat developed, these analyses led to design changes using PTC Creo which maintained temperatures at a safe range and also reduced costs towards testing. • Assisted in documenting design changes and updating design catalogues using Arena PLM and SAP for part management which provided a holistic and updated view of the product lifecycle to stakeholders. • Supported the Project Management Office by working with key stakeholders across all operational units at L&G to understand and document their processes and hand-offs to improve customer experience.• Led and facilitated workshops to align with customer issue resolution processes and worked towards continuous process improvement, eliminating existing gaps in the customer support organization and reduced case resolution time considerably.

Spring, Texas, Us

• Designed 250 Drilling Operation Procedures which ranged from troubleshooting, maintenance procedures, assembly & disassembly and safety instructions for personnel training on newly installed Perisai Drilling Rig to reduce training time.• Designed and Analyzed various Heavy Machinery Rig Equipment such as Crane Hooks, Drill Pipe Clamps and Pressure Valves using SolidWorks and ANSYS for capacity testing and conducted Design Verification under SPE Standards.• Contributed in design of checklists of each procedure after considering their severity and priority which alleviated job for Rig personnel and used NX CAD to design various equipment according to standard specifications to use in manuals.

Master Of Science (Ms), Mechanical Engineering

Bachelor Of Engineering (Be), Mechanical Engineering