Platform Development - Heating Ventilation & Air Conditioning (HVAC) system.

Lead design & development activities of automotive heating ventilation air conditioning systems (HVAC) for customers in Japan, Korea and Germany.Projects handled: Hyundai NX5/NQ6 (3 zone auto HVAC)■ Analyze customer specification requirement and finalize HVAC architecture.■ Study package feasibility for HVAC based on configuration as per customer zone data.■ Analyze vehicle interface, duct outlets and mountings with HVAC data.■ Determine evaporator, heater, PTC, motor, filter specifications as per customer requirement.■ Prepare Y0 section to match with HVAC outlets by considering evaporator, heater, PTC, & door positions.■ Create 3D model of base HVAC to extract CFD data for simulation as per TCC methodology.■ Analyze CFD results and optimize HVAC data to meet customer specification.■ Attend weekly meeting with customer to discuss project status and open points.■ Prepare detailed 3D design including sealing, guiding & mountings of HVAC for proto data.■ Analyze bench test results and fine-tune HVAC if required after meeting with customer.■ Prepare serial HVAC data considering tooling feasibilities (DFM) and design for assembly (DFA).■ Ensure Valeo norms followed in the design and prepare review checklist.■ Do thickness & clash analysis, and prepare checklist.■ Manage data in PLM for customer delivery.

Designing of complete heating ventilation & air conditioning systems (HVAC) within the package limitation for customers in Japan, Korea, India and Germany.Projects worked: Nissan (XN174A, N182A, N203A), BMW (NCAR), Hyundai (NX5/NQ6, TK), Suzuki (J021A, J022A), etc.■ Analyze customer specification requirement and finalize HVAC architecture.■ Study package feasibility for HVAC based on configuration as per customer zone data.■ Analyze vehicle interface, duct outlets and mountings with HVAC data.■ Determine evaporator, heater, PTC, motor, filter specifications as per customer requirement.■ Prepare Y0 section to match with HVAC outlets by considering evaporator, heater, doors, etc.■ Create parametric modelling of HVAC casings like distribution, divergent, air intake, etc.■ Create 3D model of base HVAC to extract CFD data for simulation as per TCC methodology.■ Analyze CFD results and optimize HVAC data to meet customer specification.■ Attend weekly meeting with customer to discuss project status and open points.■ Prepare detailed 3D design including sealing, guiding & mountings of HVAC for proto data.■ Analyze bench test results and fine-tune HVAC if required after meeting with customer.■ Prepare serial HVAC data considering tooling feasibilities (DFM) and design for assembly (DFA).■ Ensure Valeo norms followed in the design and prepare review checklist.■ Do thickness & clash analysis, and prepare checklist.■ Manage data in PLM for customer delivery.

Specialization - Progressive Die Design• Analyze sheet metal components for manufacturing feasibility.• Consult with customer for quality requirements of components.• Design 3D model of component as per customer drawing and offset the tolerance.• Unfold the product as per standard procedure and get approval from leader.• Design stamping layout by considering the pitch and width.• Consult and negotiate with production and quality team for tooling and component quality requirements.• Design punch, die insert and 3D die structure based on the layout.• Generate 2D drawing and specify the tolerance requirements.• Select material for each die components based of the function of parts.• Upload the drawing files into the BOM system and prepare Bill of Materials (BOM).• Prepare machining process flow for each component and release drawing for fabrication.• Follow-up the fabrication process and solve quality issues during assembly and trial run.• Follow-up Tooling Pre-Qualification (TPQ), evaluate component quality and review Sample Evaluation Report (SER).

• Worked in different areas including; ◊Project planning◊Component design◊Tool design & development◊Simulation and analysis◊Machining and heat treatment process◊Tooling Assembly, trial run & maintenance◊Quality control & component sample inspection.• Specialized in Metal tooling design including Progressive stamping die and Prototype tooling.• Sheet metal modeling and unbend drawing development.• Designed prototype tool for sheet metal components like lamination, terminal, commutator, etc.• Hands-on experience in various machining process including CNC milling & lathe, EDM, wire-cut EDM, grinding, etc.• Gained knowledge about Deep drawing dies, Injection mould, Motor assembly process, Lean manufacturing, Quality control, Genba Kaizen, etc.• Gained knowledge about Design for Manufacturing (DFM), QFD, SPC, MSA, FMEA, etc.