Sunil Kalyankar

Product Design Engineer with over 8 years of experience specializing in sheet metal component design and development. Demonstrates strong expertise in CSM, BOM management, and applying design and manufacturing principles such as DFMEA, PFMEA, DFM, and DFA, along with precise dimensioning in accordance with ASME GD&T and ISO GPS standards. Skilled in engineering change management processes, including ECO and ECR, as well as reverse engineering through CAD model development from physical components and validation against prototype models.

Well-versed in medical device regulatory standards, including ISO 14971 and ISO 13485, ensuring compliance and quality throughout the product lifecycle.

Lead Engineer - HCLTech

(2022-12)

Part of the internal improvement project for transfer chamber module. Worked on complete Semi-Equipment installation drawings as per FAB requirements. SD and 2D FAB templates as per customer standards & requirements.

• Carries out product selection including product specifications, material selection, design and detailed product drawings.
• Responsible for project planning and executions within delivery deadlines
• Prepares assembly & manufacturing drawings for frame weldments, lid assembly, gas box detailing, vacuum chambers and Sub systems etc.
• Investigated defective parts to pinpoint root causes and drive implementation of corrective actions
• Responsible for team defect preventive analysis, Corrective and preventive actions and SM presentations.
• Worked with direct customer requirements in FAB for complete semi equipment installation drawings and 2D templates design.
• Handling teams ECRs, New OEM part library creations and TCE data release.
• Expertise in DAR idea, BOM management, Kitting/ Structuring, tool Assembly management.

Design Engineer - Bosch - Bangalore

(2022-02 - 2022-12)

• Design & Development of Sheet metal components & their bending calculations
• Engineering change requests (ECR), Engineering change orders (ECO), and maintain the bill of materials (BOM).
• Designing oil and gas-pressurised piping – Schedule & Tube, flexible and hose piping and integration.
• Preparing the engineering drawings and design-related documents (CSM, BOM, DFMEA, PFMEA)
• Implement design for manufacturability, Design for Assembly and servicing during the design stage.
• Created the ISO GPS drawings for sheet metal, piping, and functional components.
• Checking the standards to ensure that the drawings conform to the design standards and effectively prepare the parts list and assembly procedure based on the drawings.
• Good knowledge and hands-on experience with ISO GPS standards. Geometric Dimensioning & Tolerances (GD&T).
• Handling the EQM activities.
• Design support for the lab test samples.

Design Engineer - HCLTech

(2021-06 - 2022-01)

Design and Development of Medical Equipment. Engineering change request (ECR) and Engineering change orders (ECO) & to maintain the bill of materials (BOM). Preparation of production drawing. Good Knowledge about Medical Devices ISO 14971 & ISO 13485.

Design Engineer - Vital Emerging Technologies - Bangalore

(2019-10 - 2021-06)

Research and design new parts for the Beer chiller and ambient carbonator Apply design tools like Solid works, GD&T and tolerance stack up to obtain newly designed parts, and work with suppliers and internal engineering resources to obtain prototype and new parts.

• Engaging in all phases of new product development, including concept, architecture, documentation, design, prototype, test, supplier interfaces, manufacturing introduction and service support.
• Evaluate and demonstrate manufacturing feasibility and technical justification for the design approach, conduct DFMEA, DFM and DFA.
• Maintaining documentation of design activities and responsible for complete design cycle for concept generation to final check and releasing the drawings to production.
• Maintain open communications with customers and suppliers and assist in providing technical support to meet their expectations.
• Strong knowledge of manufacturing methods (Machining, welding, injection moulding and sheet metal operations like Press brake, bending and folding).

CAE Trainee Engineer - CADMAXX Solutions - Bangalore

(2019-01 - 2020-05)

Knowledge of Finite Element Analysis, Applied Solid Mechanics and Numerical Methods within an automotive product development environment.

• Done meshing for automobile components

Assistant Quality Engineer - RAAJA Magnetics Limited - Bangalore

(2015-11 - 2016-11)

• Inspection of Stators and Rotors for Electric Motors, Inspection of silicon coils for different grades of material
• Root cause analysis, CAPA for customer complaints
• Working on 7 QC tools, KAIZEN and Control chart
• PFMEA & DFMEA
• Give dimension and tolerance for gauges to tool room
• ISO Documentation

M.Tech - Machine Design - National Institute of Engineering (2016 - 2018) Mysore

B.E - Mechanical Engineering - Navodaya Institute of Technology (2011 - 2015) Raichur