Headline

Sr. Mechanical Engineer | Mechatronics Certified | Six Sigma (DFSS) | NPD • VAVE | DFM/DFA • DFMEA • Phase-Gate Delivery | Creo • NX • SolidWorks • Windchill | Driving Innovation & Sustainability

About

My focus is simple: Deliver designs that perform, survive environmental and reliability requirements. Design to reduce manufacturing cost — ensuring design trade-offs between cost, performance, reliability, and acoustics to meet market requirements (MRD). Designs don't fail in testing. They fail in review—or on the shop floor. I make sure that doesn't happen. I am working as a Senior Mechanical Design Engineer for 7+ years taking products from concept to mass production across Industries like HVAC, Manufacturing, Consumer Electronics, Medical Devices, and Aerospace & Defense. What I actually do: - Lead end-to-end New Product Development through phase-gate processes — from requirements and concept to prototype through design validation, tooling, and finally mass productions. - Drive cost reduction, VAVE programs and DFM/DFA analysis on injection molded, sheet metal, machined, and die-cast components — avoiding expensive decisions before design freeze. - Apply structured reliability and quality methods — DFMEA, DVP&R, RCA, GD&T, tolerance analysis — as part of the design process, not as a final check. - Work across CAD and PLM environments: Creo parametric, NX, SolidWorks, Autodesk Inventor | Windchill PLM | BOM management, ECR/ ECN/ ECO configuration control and engineering change management. - Align cross-functional teams — engineering, manufacturing, procurement, and leadership — across geographies to hit CTQ requirements and overall QDC targets. What I'm looking for: A senior mechanical design or product development role where design decisions are taken seriously — and where the standard isn't just "does it work" but "can it be built, at cost, at scale, reliably." If you're hiring for that kind of engineer — or know someone who is — let's connect. Major areas of expertise: Electro-mechanical Design (DfX) | Tolerance stack up Analysis | PLM Windchill | Configuration Management | Six Sigma (DMAIC) | Reliability Engineering | BOM Management | Cross-functional Leadership.

Location

Bengaluru

AI stack

claude

gemini

kimi

obsidian

openai

perplexity

Work experience

Senior Product Development Engineer at Teamware Solutions, Mar 2023 - Present · 3 yrs 9 mos, Bengaluru, On-site client: Trane Technologies What I Do: End-to-end product design from concept to production, ensuring Quality, Performance, and Cost targets via DfX (DFM, DFA, DFS). Drive design reviews with global SMEs, support prototyping/engineering build/test/validation. Solve issues using DFMEA, DVP&R, RCA, FEA, and 9-Step problem-solving, VAVE tools (DOE, teardown, benchmarking) for cost optimization. Who I Help: Collaborate with SME stakeholders, cross-functional teams (manufacturing, quality, testing), and production partners to validate designs and mitigate risks. Partnering with Business units (SBUs) and Product Management to scale revenue and improve margins via engineering solutions. Results I Deliver: Optimize costs by 20-30%, improve quality yields by 25%+, accelerate development timelines, and resolve field issues (Q&R)—delivering reliable products at scale. End-to-End Product Development: Led concept-to-production for HVAC assemblies, complying GD&T and DfX to meet Quality/ Performance/ Cost goals—reduced development cycle from 18 to 12 months—200K+ unit launched. DfX Optimization (DFM/DFA/DFS): Applied DFM/DFA on motor base, fan mountings, cutting assembly steps by 40% and service time by 35%—saved $200K annually in labour/ manufacturing costs for China manufacturing projects. Stakeholder Collaboration & Validation: Partnered with SMEs for design reviews and prototype validation (engineering builds/ tests), resolving 15+ technical risks of commercial HVAC products via DFMEA/DVP&R—achieved 98% first-pass yield in production. Problem-Solving & Risk Management: Used FEA, RCA, and 9-Step/ 8D methodology to fix vibration failures in compressor line prototypes, mitigating 25% failure risk— secured $500K savings for commercial units. VAVE & Cost Reduction: Conducted VE teardowns/ benchmarking/ DOE on existing AHUs, identifying material swaps that lowered costs by 28% while maintaining performance—optimized $1.2M portfolio across North America and EMEA.

Design And Development Engineer at Jindal Aluminium Limited, May 2022 - Mar 2023 · 11 mos, Bengaluru, Product development, manufacturing optimization, and cross-functional collaboration. I leverage Design for Excellence (DfX) to deliver reliable, cost-effective designs—reducing Time-to-Market by up to 35%, cutting costs by 25%, and boosting manufacturability in high-stakes projects. DfX Optimization & Time-to-Market Reduction: Led DfX implementation on SPM components, slashing prototype iterations from 8 to 3 cycles—accelerating Time-to-Market by 30% while improving reliability for 500K+ unit production runs. CAE/FEA Simulation Coordination: Collaborated with simulation teams on non-linear FEA for complex gearbox assemblies under thermal-structural loads, resolving 20% overdesign issues and preventing field failures in APAC market deployments. GD&T & Tolerance Stack-Up Mastery: Applied ASME Y14.5-2009 GD&T to redesign sprocket-mount interfaces, reducing tolerance stack-up variations by 40%—enhancing assembly yield from 85% to 98% and saving $150K in rework costs. Vendor Development & New Tech Integration: Partnered with sourcing/vendors to qualify OEM motors and advanced cast iron grades (EN standard), cutting material costs by 22% and enabling DFM for high-volume marine propulsion systems. Component Selection & Material Innovation: Performed calculations for bearing/gearbox selections in multi-axis actuators, switching to tempered alloys that boosted fatigue life by 50%—solving vibration failures in earthmoving equipment.

Mechanical Design Engineer at IAC Electricals, Jul 2021 - May 2022 · 11 mos, Kolkata, Product Design/ redesign & VA/VE: Drive cost-down initiatives using Value Analysis/Value Engineering on hardware components for manufacturing and sourcing teams—reduced material costs by 27% (350K savings) without quality loss, resolving overbudget issues in high-volume forging production. Support cost justification & risk analysis: Perform risk assessments for design changes with procurement and quality stakeholders—accelerated approval cycles by 40%, enabling 150K-unit launches with zero cost overruns. Optimize DFA/DFM for assembly efficiency: Redesign parts to eliminate reorientations in hardware assemblies—reduced scrap by 32% and saving 180K in rework. Troubleshoot processes & equipment: Lead root-cause troubleshooting on assembly lines with maintenance and ops teams—improved equipment uptime by 28% via FMEA-driven fixes, increasing throughput by 25% during operational upgrades.

Design Engineer at Premium Industrial Solution Private Limited, Aug 2019 - Jul 2021 · 2 yrs, Greater Kolkata Area, Design sheet metal panels/ cabinets/ enclosures: Developed IP rated, corrosion protected concepts compliant with seismic/ wind loads for electrical and site engineering teams—delivered 120+ designs meeting IEC standards, Also reducing field corrosion failures by 30% in harsh industrial environments. Create/ update schematics & LV systems: Engineered LV interlocks, cable routing, and integrations of sensors/ PLC/ VFD/ HMI/ SCADA instrumentation (I/O modules) with automation and controls systems— supported commissioning team to fast-track processes with project documentation, on 20+ control panels (MCC, PCC, PMCC, APFC) for factory automation projects. Select electro-mechanical components: Optimized choices balancing cost/ performance/ reliability/ acoustics as per MRD for procurement and Senior engineering stakeholders— lowered BOM costs by 22% (120K savings) while achieving <45dB noise levels, resolving acoustic complaints in premium enclosures. Manage BOMs & Project documentation: Maintain cost sheets, test plans (FAT, SAT), and reports for full lifecycle, aligned with project managers and quality assurance—streamlined order to production, boosting on-time delivery from 82% to 98%

Academic Content Writer (STEM Specialist) at Royal Research, Jan 2018 - Aug 2019 · 1 yr 8 mos, European Economic Area, Developed 150+ original STEM research briefs, whitepapers, and case studies on Multidisciplinary engineering topics (Industry 4.0, Mechatronics, AI, Robotics, Machine Learning, Renewable energy system, Bio engineering—prosthetics/imaging, Design of Experiments—DOE, Aerospace Engineering) for US, UK and Australia university students and research scholars—boosted client satisfaction by 95% and secured repeat business from 20+ institutions. Conducted in-depth secondary research using IEEE, ASME databases, and Scopus supporting curriculum alignment for working professionals—synthesized complex topics into 50+ assignments/case studies, reducing research time by 40% via Zotero/Mendeley workflows. Edited 200+ academic materials for APA/Harvard compliance, eliminating plagiarism (~4% Turnitin score)—enhanced clarity and accuracy, achieving 90% approval rate on first submission. Applied precise APA/MLA/IEEE citations and formatting across 100+ online course modules for international audiences (US/Australia/Canada)—improved content discoverability by 30% through SEO optimization, driving 25% higher engagement. Collaborated with subject experts(SMEs) and editors on deadline-driven projects delivering 95% on-time for high-stakes university deadlines—created 75+ customized materials for engineering graduate programs, resolving curriculum gaps and earning 4.8/5 client ratings.

Education

Bachelor of Technology - B.Tech, Mechanical Engineering, Maulana Abul Kalam Azad University of Technology, West Bengal formerly WBUT

Diploma, Mechanical Engineering, Santiniketan institute of polytechnic