Prathamesh Chaudhari Email & Phone Number

Indianapolis, In, Us

West Lafayette, In, Us

Columbus, Indiana, Us

Lead seven new after-treatment system programs as reliability lead and providing cross-functional teams with reliability support Performed program parenting by analyzing the historical data and identifying NUD’s and delivered reliability requirements and targets Created a reliability improvement plan (RIP) by identifying the areas for improvement. Recommended reliability field and system-level test samples and developed field test plan by identifying the applications and operating conditions for low reliability risk Led 7 step problem solving (FIRG / FRACAS) to resolve the failures seen on field test units, using tool like Root Cause Analysis (RCA) and highlighted the risk to customer and MRG’s Participated in iDFMEA and lowered severity and detection risk Performed Weibull analysis, using Reliasoft Weibull++, and determined the failure behavior through the warranty period and at the end of useful life (EUL) and helped in creating warranty terms.  Performed various reliability, survivability, and warranty analysis and predictions using JMP and Minitab Performed reliability growth analysis, using Reliasoft RGA, by gathering field test data and ensured launch targets were met Performed reliability launch risk assessment to evaluate new product launch readiness and indicate risk measures. Conducted reliability functional reviews and participated in design reviews and facilitated reliability section Completed a six-sigma project on improving the product reliability deliverables by optimizing the input data

Gillingham, United Kingdom, Gb

Worked with Delphi through TASI. Recruited in the research team to perform the testing of active safety features to be installed in upcoming BMW automobiles to measure their performance and reliability Managed a team of 4 and established installation and optimal positioning of hardware setup inside a BMW vehicle for finding optimal data collection points. Executed hardware and software setups before each test  Collected different field data using Lasers, Optitrack Motive, different camera, and ADTF interfaces. Verified collected data if within defined bound and provided feedback on flaws to the development team.  Provided detailed documentation and reporting after each test. Troubleshoot field issues Executed more than 700 tests on more than 150 test subjects and established a good relationship

West Lafayette, In, Us

Worked with the research team in Honda in developing BIW structures like a crash box, srail & bumper which conforms with FMVSS, NHTSA, and USNCAP safety standards Built finite element and material models of BIW structures in Hypermesh, Hypercrash and Ls-PrePost using design inputs from clients (Honda, GM) and performed crash analysis using Radioss or Ls-Dyna Optimized origami-inspired crash box design by generating a design of experiments (DOE) using the design inputs received from Honda (Patent on this design). Achieved progressive collapse for high-speed impact with a 10% reduction in weight Executed multi-objective optimization (MOO) of Srail design (from GM) and identified an optimal balance between mean crush force and specific energy absorption using Pareto-Optimal set. Increased energy absorption of design by 6% while maintaining the same mass Involved in an experimental and analytical study of the behavior of composites and metals under high strain rate loading with Kolsky / Split Hopkinson bar. And developed a compliant mechanism for lateral energy dispersion using in-house code Worked with FEA models with materials like metals, FRP, and plastics; for optimization used in house algorithms and Hyperstudy; Used Solidworks for CAD

Munich, De

Collaborated with product development team (PDT) in Germany on creating a new low voltage 50kVAr contactor for capacitor switching while conforming to IEC 60439 standard Designed and developed different parts of contactor like plastic enclosure, metal contact mechanism, plastic snap-fit mechanism, silver contacts and springs Performed FEA analysis in ANSYS; specified analysis type, boundary conditions and required results for design validation Generated 3D assemblies and drawings in Siemens NX in accordance to ANSI Y14.5/M and managed in Teamcentre Conducted Reverse Engineering (RE) on different competitive products for design studies Created DFMEA and formal reports for every design change and presented to chief engineers Executed Clearance study, Tolerance and Stack-up analysis of assemblies and critical components Built more than 30 prototypes and tested them for mechanical endurance, shock & vibration, and drop tests

Worked with product development team in re-engineering a 10 Amp Rotary Cam Switch conforming to IEC/EN 60947 Resolved customer complaints by redesigning a cam mechanism and solved an arcing problem; Increased life by 7% Incorporated warranty improvement and cost reduction issues for re-engineering the 10 Amp Rotary Cam Switch. Incorporated warranty improvement and cost reduction issues for re-engineering chassis components; reduced product size by 4% Performed Stress-Strain Analysis on cam contacts and enclosure in ANSYS; 3D models were built in Creo / ProE Diagnosed contact welding due to the arcing problem by performing Root Cause Analysis (RCA)

Doctor Of Philosophy - Phd, Mechanical Engineering

Master’S Degree, Mechanical Engineering

Bachelor’S Degree, Mechanical Engineering