Made tactical operational and administrative decisions to meet project goals as a part of Tesla Energy leadership team. Hired, coached, and managed 2 industrial engineers, 1 mechanical engineer, 4 engineering technicians, and 2 mechanical engineering interns. Partnered with a diversified team of supply chain and operations engineers & managers, to setup regional inventory at key strategic locations globally, resulting in an annual savings of over $500K. Re-engineered the global fulfilment process to reduce the backlog of service tooling by over 90%. Led a team of 5 diversified engineers to solve multiple field failures using the principles of Root Cause Analysis. Led a complex team of over 50 field service technicians and 7 territory managers to successfully implement these solutions and complete multiple containments, on time, resulting in savings of over $60M. Led a team of 3 diversified engineers to set-up QC process for service parts and tools reducing field downtime by over 23%.

Hired, coached, and managed 2 industrial engineers, 2 mechanical engineers, and 2 engineering technicians. Mentored Industrial and Design Engineers to further develop individual expertise and learn team working skills. Led a team of 2 industrial engineers in successfully developing service manual for various industrial and commercial energy storage solutions. Conducted cycle time study and developed tools and jigs to reduce installation time by 22%. Led a team of 2 industrial engineers and 4 technicians to improve the efficiency of energy warehouse by 18% by implementing an efficient process layout. Successful early installation and commissioning of multiple projects resulting in an incentive savings of over $5M.

Worked on senior leadership bench, making operational and administrative decisions ensuring project goals were met. Hired, coached, and managed 15 manufacturing operators in a union environment. Mentored Control Engineer to further develop individual expertise and learn team working skills. Streamlined data collection throughout the plant for problem identification.Performed PFMEA and developed action plans to remove bottlenecks in processes. Reduced scrap by 25% on automated line by implementing SPC. Review, approval, and disposition of non-conformations as per standards of PRB and MRB. Redesigned work instruction into a hyper-efficient, visual, and easy-to-understand document.

Managed and coached 12 manufacturing operators in a union environment. Introduced and validated design specifications and shop floor application of new product, tools, or equipment. Programed the Automated stator bar forming machine for large scale generator.

Led a cross-functional team of 5 manufacturing and design engineers and hourly workers in lean action workout to reduce waste and rework in stator line. Quality assurance of products, services, manufacturing processes. Championed successful implementation of SPC control throughout the plant.

Led a cross-functional team of 11 manufacturing and design engineers in developing and introducing an epoxy-based end-winding bonding process for large generators in factory with a cost savings of over $1M annually. Determined the functional system design requirements for a specialized paint booth to support current and future requirements of the shop. Successfully led a team consisting of 17 manufacturing and design engineers while interacting with union hourly personnel in development of advanced manufacturing process and design changes using NX and Solidworks.Developed and qualified advanced manufacturing process for stator frame preservation while leading a team of 12 engineers and working with domestic and overseas suppliers resulting in a cost savings of over $700K annually. Performed the modal analysis study of winding structure to understand and validate epoxy-based end-winding bonding process.

Trained and Mentored 2 technical writers and 2 standardization engineers in the development of repair procedures. Responsible for the development of preventive maintenance for oil and gas drilling equipment. Investigated the existing product failures and identify the failure location using NDE inspection procedures (UT, MT, etc.). Generated detail rework procedure to restore the equipment for continued service using CREO and Inventor. Extensively used API and ASME standards.

Trained 15 design engineers to use ABAQUS to simulate and avoid failure in composite matrix and steel drill bit. Designed, developed, and sourced a new downhole drilling tool (drill bit) which resulted in 50% reduction in drilling time and a cost savings of $250K annually. Recognized for the successful completion of the project with a promotion. Developed thermo-mechanical coupled FE simulation technique in ABAQUS to avoid the blade failure in composite matrix and steel drill bits and propose design changes using Pro/E and CREO. Used GD&T for tolerance study. Successfully predicted the fatigue life of a threaded connection for a new product using numerical techniques, FE-Safe and ABAQUS.

Successfully completed the sub-contracted project on-time and within budget avoiding over $10M in cost to quality. Performed Root Cause and Fretting analyses of a wear failure characteristic in composite stator bar insulation.Leveraged Six Sigma in the development of a novel technique to mitigate the wear failure. Performed ANSYS finite element analysis to model the wear characteristics in stator bar insulation and to validate the solution. Performed Failure modes and effects analysis (FMEA) to identify the possible failures on the proposed solutions.

Developed numerical model to quantify and predict the failure from the onset to complete structural collapse. Investigated the effects of explosive loading and high-speed impacts on aerospace and vehicular structures.

Experimentally investigated the effect of curvature on dynamic response of aluminum panels used by the US Air Force. Developed a finite element model to predict the dynamic response of the panels. Studied the dynamic response of curved carbon fiber panels used by the US Air Force. Mentored 2 graduate and 1 undergraduate students in their research fields.

Investigated the dynamic behavior of CORECELL foam, which is an important core material used by the US Navy. Designed, developed, and tested glass panels to arrest shattering when subjected to blast loading. Performed extensive shock and vibrational investigations of structural and composite materials using a shock tube coupled with high-speed imaging (up to 50,000 frame/sec) and 3D-Digital Image Correlation. Assisted Dr. Arun Shukla in the writing a chapter in the book “Experimental Solid Mechanics”, published by College House Enterprise, LLC, ISBN 0-9792581-8-9.

1. Numerically simulated the modified MRAF process which was used to obtain Nano-scale surface finish on a silicon work piece. This resulted in 50% reduction in finishing time.2. Organized a short course on traditional & non-traditional micromachining, sponsored by AICTE & BARC.3. Organized tutorials to clarify course materials. Delivered lectures on ABAQUS and developed a new examination technique in FEM.

Analyzed the existing rear axle assembly line and prepared a technical and financial feasibility report on a new axle assembly line in the heavy vehicle division of TATA Motors.