1. Design Engineer - Mechanical
RESUME
NAME : KARTHIKEYAN JAYAPRAKASH
QUALIFICATION : BACHELOR OF MECHANICAL ENGINEERING
TOTAL YEARS OF EXPERIENCE : Four Years and Eight Months (4.8)
KEY SKILLS : SolidWorks, AutoCAD, Mechanical Design, Unigraphics NX,
Medical Devices, ISO 13485, USFDA, Packaging, MS Office, Plastic
Product Design, Injection Mould Design, labelling
CERTIFICATION : Certification in Part-Time course of “PLASTICS PRODUCT &
MOULD DESIGN” at CIPET Chennai
MAIL : karthikeyanjayaprakash6@gmail.com
CONTACT NO : +91-9952031112
CURRENT EMPLOYER : HCL Technologies Ltd, Chennai
Goal and Objective
• To get a professional & personal growth, where I can learn, apply and share my knowledge, experience
and capabilities through team work for achieving the company objectives.
Professional Summary
• Four years and eight months of experience in Medical product design & development and other phases
of project.
• Experience in various phases of product design and development and other phases namely,
o Concept Creation, Concept selection process, Material selection process, Design calculation.
o Design for Manufacturing, Detail designing, Prototype development.
o Packaging Design and Development for new product development process.
o Performing Design verification and validation for design change, material change and etc in
existing product released in market.
o Identifying Critical to Quality (CTQ) dimensions during legacy conversion of the product and
released the updated CAD model and detail drawings for inspection process.
o Performed Tolerance stack-up analysis to compare current and proposed tolerance limit of the
same product and releasing report for the same.
o Applying GD&T symbols in the drawings for inspection process to measure the functional
design.
o Undertaking the product sustenance by creating and updating the design control documents like
Buy Specification, Specification of Finished Goods, packaging documents and Labeling and etc.
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2. Design Engineer - Mechanical
Personal strength
• Leadership
• Serenity
• Responsibility
• Learner
Trainings undergone:
• Unigraphics NX
• Solid works
• AutoCAD
• Design Verification techniques
• Statistical Analysis
• Packaging of Medical Devices
• Packaging Graphic/labelling Creation
• Geometrical Dimensioning and Tolerance
• Sterilization Techniques
• IFU content training
PROJECT 1
Project : Charging Dock for Dental Laser Surgical Devices
Tools: Solid Works 2011, MS Excel 2010
Description:
New Product development of charging dock for Dental laser surgical devices
Responsibilities:
 Understanding the customer requirements from the engineering specification and previous products of
their competitors to find out new charging dock for this device.
 Hand sketches were made along with Industrial Design team for same.
 Conducted DAR matrix study to identify the suitable concept for next process.
 Development of the selected concept is implemented and CAD model was developed on the same.
 Basic design calculations were done to identify the centre of gravity for the particular product to balance
the weight of the devices.
 Type of USB port and classes for the same was identified along with electronics team. (IPX5)
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3. Design Engineer - Mechanical
 Material selection was done for the charging dock; Zamac (AL+S.S) is finally approved. Since this
material doesn’t conduct any electric charge to avoid the risks during the power supply. Plastic
component material is PP.
 During DFM study, ultrasonic welding is preferred to attach the plastic components since both were
different in colors.
 In post DFM, the material reduction were done to minimize the cost of product, also water drian port is
introduced in the bottom of the component (ZAMAC) to prevent from water storage in IP test.
 After the Design review, the DFM drawings were released and the pilot tool was made for the same
device.
 Tolerance stack up is completed to release the product for production.
PROJECT 2
Project : Pressure Profile measurement on Laparoscopy Endo Cutter Device
Tools: Unigraphics NX5, Minitab V16 and MS OFFICE
Description:
Design and Development of Pressure Profile in laparoscopy Endo Cutter Device and developed a Test
fixture to performing Gage R&R to find out the pressure profile formation in the Devices.
Responsibilities:
 Identified the customer requirement to modify the profile of the device through engineering specification
and conducted brainstorming to identify the concepts.
 DAR/ Pugh matrix was developed to rate the concepts and design calculation was done to meet the
specifications. Prototype was developed to conduct Gage R&R.
 Conducted a mock up tissue cutting procedure to ensure the design is within the given specification.
 Design and Development of a test fixture by conducting brainstorming sessions and finalizing with a
design using Pugh Matrix selection process. Design calculation was done for the selected concept.
 Detailing the test fixture through CAD Drawing Software and analyzed the best material and
manufacturing process for test fixture Pugh Matrix selection process.
 In Parallel, Coordinating with the vendor for off-shelf components and EDM method was selected for
manufacturing process.
 Off-shelf components are calibrated using vacuum pressure instrument to conduct Gage R&R.
 Verified the manufactured test fixture and the gage R&R samples are checked before conducting the
profile measurement test.
 Devices are undergone gage R&R testing by taking various set of readings and the readings are
measured using customized software (TekScan). These raw data are pull into the Minitab and Gage
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4. Design Engineer - Mechanical
R&R graph was plotted. The graph was analyzed with three set of data and the report was shared to the
client and received appreciation for this project and selected as best project in my team.
 This test fixture was implemented in the manufactured line to measure the pressure created in the
devices.
PROJECT 3
Project : Design and Development of continous feed mechanism in Laparoscopy device
Tools: Unigraphics NX5, Microsoft Project Plan and MS Office 2007
Description:
To design and develop a continuous feed mechanisms in existing laparoscopy (Endocutter) device from
Ideation to Prototype validation.
Responsibilities:
 Requirements gathering from the customer using data collection sheet to find out the gap between endo
cutter device and continuous feeder.
 Generating concepts for the continuous feeder mechanism by conducting brain storming sessions and
consulting with Industrial Designers to give the animations and 3D hand sketch drawings for various
concepts.
 Conducting Pugh matrix selection process for concept selection, material selection.
 Converting the concepts into CAD models by using Unigraphics NX5 software detailing the same.
 Discussed with vendors to fix the manufacturing process and material selection.
 Hands on experience in prototype manufacturing and solved the technical problems during the assembly
process.
 Validating the Prototype by conducting mock tissue cutting testing and stapling. Feasibility of the
concepts is ensured by answering few questions by client.
 Released prototypes, working videos, animations and CAD models to the client through presentation.
 Solved the technical issues in first release prototypes and released as per the client requirements.
PROJECT 4
Project : Design Verification & Validation for colorant change in Hypodermic Needle Hub.
Tools: Minitab V16, MS OFFICE and Microsoft project Plan
Description:
To verify the proposed colorant in the needle hub under design verification process by comparing with
existing released product.
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5. Design Engineer - Mechanical
Responsibilities:
 Input study of the new hub colorant properties and gathering the initial process validation report from
client.
 Created new Design verification plan and protocol with appropriate test methods and mentioning the
samples required for the test based on the AQL limits and acceptance criteria levels.
 Providing the design verification approach in the same plan for customer clarifications.
 Finalizing the test methods and samples level by conducting Design review with client.
 Adding rationale to justification which test methods are not required for this colorant change project.
 Transferred the design verification plan into design verification protocol by mentioning the test methods
procedure and number samples need to procure from the manufacturing plant.
 Conducted test in India Design Centre and collecting the Test values from the technician.
 Statistical analysis will be done for the test values of raw data. Process capability will be test for the given
output data and various methods of statistical process charts are plotted in the report.
PROJECT 5
Project : Legacy conversion of the Closed Drug Transfer Device for cancer treatment
Tools: SolidWorks 2011, Pro-E Wildfire 5 and Microsoft Office 2010.
Description:
Transferring product design and creating the design control documents. CTQ of the product components
are finalized for this current product.
Responsibilities:
 Understanding the product design and product functionality by handling the product and conducting
mock up testing.
 Identifying the product criticality and behavior. That uniqueness of the product is captured in the
spreadsheet.
 Converting the CAD model from Pro-E to SolidWorks and creating the drawings for the same
components in the initial phase.
 Identifying the CTQ (Critical To Quality) dimensions by using the spreadsheet which was prepared
before the Initial phase.
 Mentioned the CTQ in the newly created drawing and shared with the manufacturing plant for inspection
purpose.
 Also creating the Design control documents as per client standards.
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6. Design Engineer - Mechanical
Beyond Work:
1. Submitted a value creation for automated macro for approval sheet in labeling project.
2. Won 1st
places in Variety (SPICE) inter-corporate cultural event organized by carrot Excel for the
year 2012 and 2013.
3. Won 1st
place in Radio Mirchi for variety Entertainment.
4. Created a Play/Skit for Orphan Home Girls and educated on the Topic of “HOW TO ACT”
6

7. Design Engineer - Mechanical
Beyond Work:
1. Submitted a value creation for automated macro for approval sheet in labeling project.
2. Won 1st
places in Variety (SPICE) inter-corporate cultural event organized by carrot Excel for the
year 2012 and 2013.
3. Won 1st
place in Radio Mirchi for variety Entertainment.
4. Created a Play/Skit for Orphan Home Girls and educated on the Topic of “HOW TO ACT”
6