1. KARAN MANDOKAR
Mobile:91-8793379440
Mail Id:karanmandokar@yahoo.com
SENIOR PROFESSSIONAL
Enterprising leader & planner with a strong record of contributions in invigorating businesses, heightening productivity, sys tems
and procedures, targeting assignments in:
Design Engineering / New Product Development
Industry Preference: R&D/D&D
PROFILE SUMMARY
Competent professional with over 10years of experience in
~Design Engineering ~New Product Development ~Project Management
~Process & Quality ~Plastic, Sheet metal, Die cast Product Design ~Value Engineering
~Pro-e Design ~GD & T ~DFMEA
 Expertise in facilitating new product development initiatives with key focus on design, planning, requirement analysis,
system design and manufacturing engineering
 Knowledge of managing Design Engineering operations involving design & development, co-ordination with internal
departments, process developments.
 Formulated design of electronic products, made of plastic, sheet metal, casting
 Steered various initiatives for concept development, design calculation, design reviews, material selection, prototype
validation, costing , BOM and final molded part validation
 Possess sound knowledge of Product Design, Value Engineering, Mould Design Process & Manufacturing Engineering,
 3D Parametric Modeling of Automotive & General Engineering Components, Drafting; proficient in Pro/Engineer, Product
and tool costing .
 Product and tool validation, international experience in South Korea and China
 Proficient in using Pro-E Wildfire-4 (Solid Modeling, Surfacing Modeling, Sheet Metal, Assembly, Drafting, Pro-e
Manufacturing, PCB ECAD to MCAD Interaction)
 Possess knowledge of Geometric Dimensioning & Tolerances (GD&T)Analysis, ,DFMEA analysis and design reviews
 Excellent interpersonal, communication and organizational skills with skills in team management and planning
WORK EXPERIENCE
Dec’09 - Sep’ 15 Emerson Innovation Center Pune, Business Unit – Control Techniques R&D for New Product
Development as Sr. Design Engineer- New Product Introductions / Development (NPD)
Key Result Areas:
 Steering daily requirements based on First Requisition Specification (FRS)

2.  Conducting product drill down studies to define components, sub-systems and system
 Ensuring product concept completion through active interaction with various functions for example
o Material selection ( UL94- Flammability rating )
o Mechanical properties
o Concept generation
o Design calculations
o Electronic component placement
o PCB design and calculations
o Thermal design
o Industrial design
o Technical support
o Design reviews
o UL/CSA Testing (Drop ball impact test, Finger probe test, Over torque test, Vibration robustness testing)
 Conducting risk analysis and providing mitigation plans
 Formulating prototyping plans and getting prototypes made
 Driving concept testing for design verification
 Tolerance stackup for assembly and parts.
 Steering DFM & DFA analysis .
 Formulating product design to make component, assembly drawings &BOM
 Material selections,Understanding manufacturing specifications e.g. assembly processes, quality plans
 Streamlining First Piece Qualifications & providing part approvals through First Article Inspection (FAI) disposition
 Product testing including mechanical shock and vibration test, drop ball impact test, IP tests
Working Knowledge of UL 508C, UL840, Value engineering
Uni-dirveM Frame 6
 It is an AC drive (power rating 15 kW)
 Contribution:
 Mechanical design of product involving plastic and sheet
metal parts
 Active involvement in various stages of product
development from concept design to manufacturing
 Successful interaction with various functional teams for
product development ,concept development, concept
presentation, pros and cons,, design finalization, design
validation ,tolerance check, prototype validation, fitment
check, mechanical and electrical tests ,check the aesthetic
appearance.
 Final models and drawing are send to tool maker to get cost
quote .After approval tool maker interaction to get final
modifications and tool samples .tool sample validation,
ISIR inspection ,drawings update and final drawing upload on team centre.
 Qualification of plastic parts for pilot and mass production by attending mould trials at supplier’s sites in China.
 Product testing qualification involving mechanical shock and vibration test ( per IEC60204) ,drop ball impact test, over
torque test, IP 54 test
 Product build manual updates, sequence of operation involves in product build as per the manufacturing line, and support
to the user manual updates.
Conduit Gland Design
 Design of conduit gland kit for Unidrive Frame-06
 Prototyping and design validation of conduit design
 Support for UL508, qualification of the conduit kit
Cold Plate System
 Mechanical system design for attachment of external cold plate to Unidrive-M Frame03,04,05 & 06
 Successful testing and prototyping of the cold plate design concept
Highlights:
 Attained recognition for Management for Invention Disclosure Filling
 Executing Cold Plate System for Uni Drive-M
 Undertaking initiatives to attach Cold Plate / External Heat Sink to a drive cold plate test setup and cold plate preparation
 Visited China for Final Product validation and Tool Validation

3.  Identified the scope for planning, implementing & monitoring of changes to enhance efficiency, design flow, working
practices, consumables, and so on for controlling and reducing the designing time
 Played a key role in new concept idea generation, product validation and product testing
Apr’08-Dec’09 MIRC Electronics Ltd. Andheri East, Mumbai- R&D for New Product Development as
Design Engineer - New Product Introductions / Development (NPD)
Key Projects:
 Xaria 2.1 Woofer Box for (42'& 32' LCD TV)
 26' Slim LCD TV, 3D modeling and detailing the internal architect
 22'' LCD TV, modeling
 Initiated Value Engineering Projects for cost reduction by replacing the metal parts with plastic parts
 Implemented the use of common parts for all the series of parts so that same part is used in many places
Key Result Areas:
 Created a 3D Model, using the concept of product design and industrial design
 Detailed the internal architecture, parting plane for the product, locking arrangement, placement of electronics PCB,
Electronic components such as heat sink, ventilation, AC-Socket, AV-Socket LED Placement. and on/off switches
 Assembled all components, checked the interference and finally the prototype is prepared for tested, aesthetic and
function wise. The Model is then sent to the Mold Makers, as per their feedback the necessary changes are implemented
 Streamlined First Piece Qualifications & providing part approvals through First Article Inspection (FAI) disposition
Highlights:
 Undertook various initiatives for cost reduction such as:
o Multipurpose functional chassis & speaker housing for cost saving
o Family mold for same material parts
o Visited South Korea for Final Product and Tool Validation
PREVIOUS EXPERIENCE
Jul’06- Apr’08 Link Well Telisystem (P) Ltd., Hyderabad - R&D Division as Design Engineer - New Product Design
(NPD)
Key Projects:
 Hand Held Terminal
 Hand Held Terminal with Impact Printer
 Hand Held Terminal with Thermal Printer
 Data Converter Devise (Optical Reader)
Key Result Areas:
 Concept generation, product design and aesthetic design.
 Detailed the internal architecture, parting plane, PCB and components .
 Assembled all components, checked the interference and finally the prototype is prepared for tested, aesthetic and
function wise.
 Mold Makers, interaction ,sample validation, final drawing up dating on PLM .
 Streamlined First Piece Qualifications & providing part approvals through First Article Inspection (FAI) disposition
Highlights:
 Undertook initiatives for product testing and launched it successfully
Aug’03- Jul’06 Bhagya LaxmiIndustries (P) Limited, an ISO 9001 Company, Hyderabad as Engineer
Key Projects:
Title: Air Cooler Design- Corner Cap, Drain Tray, Side Grills, Door Trim, G.S.L Connector, Control Box
Organization: Voltas Limited A Tata Enterprise, Sanatnagar, and Hyderabad
Type of Mold: Injection Mold
Title: 12V40Ah, 12V200Ah, 12V400Ah Battery Containers and lid
Organization: HBL NIFE Power system Ltd... Division TLAB, Hyderabad
Type of Mold: Injection Mold

4. Title: Fan housing, fan bottom, top cover, canopy, regulator cover
Organization: Yash International Ltd. Hyderabad
Type of Mold: Injection Mold
Title: Can and Disc Capacitor
Organization: Tiberwala Electronics Ltd., Hyderabad
Type of Mold: Injection Mold
Commenced work in Ordenance, Factory, Medak from Jul’2000- Jul’2001 as Graduate Engineer Apprentice Trainee
EDUCATION
2003 Post Diploma in Plastic Engineering from CIPET, Hyderabad with 70.40 %
1999 Bachelor of Engineering (Mechanical) from Osmania University, Hyderabad
IT SKILLS
 Pro-e Wild fire-3
(3D Solid Modeling, Surfacing , Sheet metal, Drawing, Assembly, Pro-E manufacturing, Core, Cavity Extraction)
 Mold Flow Analysis.
 AutoCAD
PERSONAL DETAILS
Date of Birth: 11thJuly, 1975
Address: FNo-5, Janaki Nivas, Baner , Pune 411045
Languages known: English, Hindi, Marathi & Telugu