Milan Shah Work Portfolio Contact

1
Work Portfolio
of
Milan Shah
Contact Information:
Email: milanmshah@gmail.com
LinkedIn: http://www.linkedin.com/in/milanmshah

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INDIX
 Education……………...................................Pg-3
 Patents………………...................................Pg-4
 Professional Experience:
1. FEV North America Inc.
(Onsite at GE Transportation/ Wabtec Corporation)
Senior Engineer….………………………………….…..Pg-5
1. Honeywell International Inc.
Applications Engineer….…………………..…..Pg-13
3. Butler International Inc. (EASI & Onsite at Caterpillar)
Mechanical Design Engineer..……….......…..…Pg-17
4. Jay Pumps Pvt. Ltd. (Grundfos Pumps)
Applications Engineer.....................................Pg-23
5. Shah Alloys Ltd
Graduate Engineering Trainee.…………………Pg-25
 Analysis Projects…........................................Pg-30

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EDUCATION
• M.S., Mechanical Engineering
– Wayne State University, Detroit, USA, May 2004,
GPA 3.3/4.0
• B.S., Mechanical Engineering
– Gujarat University, Ahmedabad, India, June 2000,
GPA 3.8/4.0
Back to Index

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• Patent US 20140052360 A1: Methods and Systems for an engine- Cooling of fuel
injector in turbocharger exhaust path upstream of particulate filter.
• Patent D729278: The ornamental design for a turbocharger.
• Patent D734364: The ornamental design for a turbocharger system.
PATENTS

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Company Information:
FEV is powertrain and vehicle engineering company that supplies the global
transportation industry. FEV offers a complete range of engineering services in
the design, analysis, prototyping, powertrain and transmission development, as
well as vehicle integration, calibration and homologation for advanced internal
combustion gasoline-, diesel-, and alternative-fueled powertrains. The FEV Test
Systems division is a global supplier of advanced test cell, instrumentation and
test equipment.
FEV NORTH AMERICA INC.
[www.fev.com]
Position: Senior Engineer 08/2010 to Present

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1: Turbocharger System for Tier 4 Locomotive Engine
• Packaging, ducting & integration concepts of T4 Locomotive Heavy Duty Diesel
Engine Turbocharger System for prototype and production version of hardware.
• Software Used: NX Unigraphics
• Worked with customer and suppliers to oversees all stages of the design process
including definition of requirements, conceptual design, detail design & system
validation.
• Tollgate design reviews for system requirement, concept design, detail design,
validation, component release and manufacturing review.
• Created Maintenance Instructions for turbocharger system installation and removal
instructions from Locomotive.
• eNCI and PPAP support.
Client: GE Transportation/ Wabtec Corporation
T4 Locomotive

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2: J616 Diesel Gensets Engine Project
• Created engineering quality document - Boundary Diagram, P-Diagram, DFMEA &
V&V matrix for several Engine components and Systems like Engine Cooling
System, Lube Oil System, Front and Rear End Cover etc.
J616 Diesel Gensets Engine

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3: Powerhaul Locomotive Engine Reliability Project
• Led Valve Train Reliability Issue. Root Cause Analysis, DFMEA, Verification and
Validation activities to repeat failure, finding root cause and provide containment
solutions.
• Supervised Endurance Test on Locomotive. Created test plan, inspected engine at
regular intervals and after completion of the test and prepared final report.
Powerhaul Locomotive Engine

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4: Tier 4 Locomotive & Marine Validation Projects
• Strain Measurement and Temperature Survey for various Tier 4 Locomotive and
Marine Engine components like Liner, Strongback, Valve Guide, Injector Bolt,
Injector clamps.
• Global Vibration Survey for Tier 4 Locomotive & Marine Engine (Included all the
engine components).
o For Strain Measurement, Temperature Survey and Global Vibration Test-
Created test plan, testing, data processing (used LMS Software), and report
creation.
T4 Locomotive T4 Marine Engine

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5: Engineering Test Lab Support Projects
• Battery Electric Locomotive, Battery Test Lab, New York City Transit
Locomotive & Dual Fuel Locomotive Test Facility Development
o Project/Program management, planning, concept generation, layouts, bid
package creation, execution, procedural document, worked with sourcing,
contractors, suppliers & cross functional teams.
o Led the Projects ranging from $800K to $3.5M
Battery Electric Locomotive Dual Fuel Locomotive

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• Calibration Support
o Created calibration process flow chart, procedures, proposals, process
improvements, trained personals and automated calibration tracking reporting
for Engineering Labs.
• Budgetary Planning
o Created budgetary planning requirements for Engineering Labs. Worked with
business leaders and cross functional team to identify budget requirement for
product testing, resolve safety concerns and facility upgrades.
• Fixture and Platform Design
o Designed engine base mounting fixtures in test cell and raised locomotive
platform to resolve safety issue.
•Propulsion and Air Compressor Test Lab
o Test lab setup, BOM creation, coordination, commissioning & test budget
estimates.
Back to Index
5: Engineering Test Lab Support Projects

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6: Miscellaneous Projects
• Dual Source Engine Components
o Engineering support for engine components dual source PPAP activities like
creating validation plan, answer any supplier queries, approves validation test
results from supplier.
• Dual Source Bearing Project
o Requirement & detail design reviews for Loco Axle, U-Tube, Traction Motor
Bearings, AC Drill Motor Bearing and Komatsu Truck Wheel Motor
Bearings.
• T4 Loco British Rail Endurance Testing Support
o Inspection & evaluate of all the engine components and create final report.
Back to Index

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Honeywell International Inc. is the fortune 500 company operates as a diversified
& manufacturing company worldwide. Honeywell Turbo Technology Division
for which I’ve worked for is part of the Transportation System; expert in
development and manufacturing of Journal Bearing, Ball Bearing, Double Axle
VNT, AVNT and Series Turbochargers for Passenger Cars, Light Trucks,
Medium & Heavy-duty Vehicles Applications.
HONEYWELL INTERNATIONAL INC.
[www.honeywell.com]
Position: Applications Engineer 05/2007 to 05/2009

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1: On-Site Customer Support
• On-site turbocharger testing support for Tier 4 development on-highway and off-
highway engines, Tier 3 product issues related testing
o Helped with creating test plan, instrumentation, running the test one engine or
vehicle, data evaluation, test plan and final test report.
o Inspection of turbocharger components before and after testing.
o Hands on experience with turbocharger shaft motion testing.
o Worked with cross functional team.
• Customer support & relations
o Be the first point of contact for customer with any queries related to testing,
requirement for new application, R&D projects, matching turbocharger for
any new application, field failures, on-site meetings with customer,
coordinating design and product related questions with engineers at company
headquarter.
2: Turbocharger Production Support
• Supported production plant for Caterpillar C13 & C15 Turbochargers
o Supported any engineering quality, assembly line, testing issues for the
turbocharger production line.

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3: NPI & CPI Projects
• Supported various Tier 3 New Product Introduction (NPI) & Continuous Product
Improvement (CPI) projects for Caterpillar C13 to C32 Engines
o Creating program timeline.
o Turbocharger matching for new applications.
o Helped Business account manager to submit proposal and generate Bill of
Material for any new request from customer.
o Worked with suppliers for component level testing, timeline, PPAP activities,
manufacturing issues etc.
o Worked with Product Engineering team for turbocharger verification and
validation activities, test plan on engine.
o Worked with Design Department to create and release internal turbocharger
assembly drawing, customer specific turbocharger outline drawings and
maintenance instructions.
o Completed Production Launch activities.
4: Six Sigma Green Belt Project & Certification
• Successfully completed Turbocharger Oil Coking Issue Six Sigma Green Belt
project and received Green Belt Certification
o Supported project with Pugh Matrix, DFMEA, Design of Experiment (DOE)
& DVP&R activities. Received Six Sigma Green Belt Certification.

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5: Turbocharger Reliability Project Support
• Supported various Field failure issues for Caterpillar C7 to C32 Engines (Small and
Medium duty turbochargers)
o Teardown and Inspection of failed field return turbochargers at customer
facility with the help of Field Service Engineer. Hands on experience with
teardown.
o Provide rapid containment solution for any field failures.
o Worked with Product Engineering team to generate root cause analysis tree,
generate possible solutions, Pugh matrix to select final solution and provide
permanent corrective actions for failure issue.
o Planned and managed timeline for rapid containment and permanent
corrective actions.
• Supported Design, Development shop, and Lab with issues pertaining to Shaft
Failure, Turbine Housing cracking, Pin wear, Ball bearing, Noise, Actuator Failure,
component interference, oil coking etc. for On-Highway and Off-Highway Engine
Turbo programs resulting in deduced warranty costs.
Back to Index

17
BUTLER INTERNATIONAL INC.
[www.butler.com]
Position: Mechanical Design Engineer 08/2004 to 05/2007
Butler International Inc. is a leading provider of Tech Outsourcing services,
helping customer worldwide increase performance and savings. Butler’s global
services model provides clients with onsite, offsite or offshore services delivery
optional customized appropriately to their unique objectives. At Butler, I’ve
worked for 2 different clients; Engineered Air System Inc.- Offsite Butler Office
and Caterpillar Inc.- Onsite

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• Extensive use of Pro/E 2001 for redesigning, restructuring and digitization
of Minuteman Launch facility and Missile Alert Facilities.
Client 1: EASI (Engineered Air System Inc.)
[www.easistl.com]
1: Minuteman Launch and Missile Alert Facility Projects

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• Solved the tolerance and interference issues during re-engineering of Bare Base &
Air Ash Heater as a part of Critical Design Review.
• Re-designed internal parts of Air Ash Heater so that it can fit in Bare Base Heater
Structure since Air Ash Heater was a big unit.
Army Space (ASH) Heater Bare Base Heater
2: ASH and Bare Base Heater Redesign Projects

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• Used Top down design approach & provided technical support for the conceptual
projects of next generation electronic powered Chemical Biological Protective
Shelter System-CBPSS
• Re-designed Control Panels, Transformers, HVAC Components, Duct Design,
Structures of Chillers using Pro/Sheetmetal, Pro/Piping & Pro/Cabling.
• Concept design of POD & Shelter Assemblies for CBPSS using Pro/Sheetmetal.
3: CBPSS Concept Design Project

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1: Concept Design & Packaging of Open Crank Case Ventilation System (OCV)
Low Mount Version to meet emission regulations of upcoming heavy duty engines
Details:
As engine reduces exhaust emissions, crankcase blow-by vented to the atmosphere has
become a larger contributor to the total emissions. To further reduce the total emissions of
engines, it was becoming necessary to rout these gases into the air intake system. Crankcase
blow-by is produced when combustion gases, under high pressure, become contaminated
with oil mist when blown past the piston rings into the crankcase.
Client 2: Caterpillar Inc. (www.cat.com)

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2: Concept Design of Exhaust Manifold for 2010 Heavy Duty Engine
• Used Advanced Pro/Surfacing for Exhaust Manifold Concept Design. Received
Certificate of Appreciation from Caterpillar Engine Research for this project.
3: Purpose Built Engine Project
• Concept Design & Development of Exhaust & Cooling System to increase the
efficiency & meet emission regulations of On-Highway Heavy Duty Truck Engines.
4: Pro/E Fluid Line Design for Engine Installation & cooling arrangement
• Turbo Supply & Return Lines, Extension pipe design for CRS (Caterpillar
Regeneration System), Ducting for Cooling Arrangements of Off-Highway Truck
applications & Fuel Lines.
5: Design Solution for field & shop floor related issues of engine
components of current production
• Provided Design Solution for switching Gears in Engine Arrangement ,Oil Remote
Unit Assembly needed 3 wrench for assembly, Fuel Line Issues (Kinking, Twisting &
Fouling Problems), Fume tubes, Oil Guide Locking Mechanism.
Client 2: Caterpillar Inc.
Back to Index

23
JAY PUMPS PVT. LTD. (GRUNDFOS PUMPS)
[www.jaypumps.com]
Position: Applications Engineer 07/2001 to 04/2002
Jay Pumps Pvt. Ltd. is authorized distributer of Grundfos Pumps. Grundfos is one of the
largest pump manufacturing companies in the world with annual production of more then
10 Million Pumps manufacturing Circular, Multistage Centrifugal Pumps, Submersible,
Sewage pumps etc. which provides pump solutions for various applications like Heating
Systems, Cooling Systems, Industrial Applications, Pressure Boosting Systems,
Groundwater & Domestic water supply, Wastewater & Environmental applications.

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Design Solution & Customer Service:
1: Design Solution for Pressure Boosting System
• Built up a system in which Submersible Pump can be used as a Pressure
Boosting System in which cost was 20% less than the system in which
Multistage Centrifugal Pumps or Self Priming Pumps were used.
2: Customer Support by Designing Piping System
• Designed a piping system in which customer can use both overhead tank &
pressure boosting system, so in case of electricity failure customer can use
water from overhead tank.
3: Customer Support by providing correct Centrifugal Pump
• One of the customer was asking a Centrifugal Pump with particular head
which was not available in Grundfos Series. So the solution given is reduced
one impeller of the Centrifugal Pump to get the desired head.
JAY PUMPS PVT. LTD. (GRUNDFOS PUMPS)
Back to Index

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Shah Alloys Ltd. is the second largest stainless steel producer in India with a
production capacity of more than 36000 tons per month. It specializes in slabs
(1800 x 240 mm), billets, blooms, bars etc.
SHAH ALLOYS LTD.
[www.shahalloys.com]
Position: Graduate Engineering Trainee 07/2000 to 12/2000

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Problem Solving Efforts:
1: Overheating of a portion of ladle – side wall
The heat from the AOD converter was tapped in a 50 Metric Ton ladle and
was lifted over to a continuous casting station. The ladle was a carbon steel
vessel lined internally with Alumina bricks. The ladle was purged with Argon
gas from bottom through a purging nozzle.
Given Solution:
• The solution of this problem lies in the stirring of the heat bath. When studied
carefully and with the help of computer simulation, it was observed that a
turbulent flow was created near the wall due to purging of argon gas. The
region of the ladle wall which was exposed to this turbulence used to get worn
out faster than the rest of the portion of ladle.
• Hence, I redesigned the injection nozzle so as to create a sufficient stirring
ratio effective for quality steel production and simultaneously to ensure that
the turbulence does not effect locally over a portion of ladle.
SHAH ALLOYS LTD.

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2: Drop in ladle temperature
It was observed that there was more than 25°C temperature drop in the heat
from tapping point to casting station. This used to impair the casting quality
and simultaneously added to energy expenditures.
Given Solution:
• On carefully analyzing the process data history, and the design conditions of
the ladle, it was observed that despite of sufficient preheating, the heat loss
was found to be more from the side ways due to conduction and convection
mechanisms. As a result, the unilayered insulating wall was modified into a
double layered wall with a fire clay brick layer. This leads to a temperature
drop to 13°C and improved the quality of casting.
SHAH ALLOYS LTD.

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3: Customer Support for heat treatment dies
Our customer was using heat treatment dies for brass extrusion mill made from
our material. The customer intended to switch over to a new material which
was not under our scope of supply. The problem faced by the customer was
frequent material sticking, longer downtimes for maintenance of dies, increase
in dimensions due to frequent filing operations etc. This led to a decrease in
quality of the extruded bars and also impaired the production.
Given Solution:
• Instead of switching over to a new material, I suggested them to carryout a
new process which improved their surface properties without changing the
bulk. As a solution to their high temperature wear problems, I suggested them
Plasma Nitriding to be carried out on hot die steels. This led to improvement in
wear resistance, non-sticky surface, reduced downtimes and increased
production. It helped the customer reach 4 sigma rating.
SHAH ALLOYS LTD.

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Design Solution for Water Cooled After Cooler:
4: After cooler was not giving good efficiency
Given Solution:
To Increase Cooling Temperature Difference (CTD) of after cooler, cooling
coil was re-designed. Inlet of the water was kept at the outlet side of air, which
reduces thermal stresses & allow maximum heat transfer.
SHAH ALLOYS LTD.
Back to Index

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Crank Lever Design & Optimization Project using Finite Element Methods
(FEM):
• Design a Crank Lever with the given dimensions such that Force (P) during
the panic braking is five times that of Normal braking.
• Software used: Hypermesh & Nastran
Academic Analysis Project

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• It is observed that the region showing in blue color has minimum Value of von
misses stress so, we can reduce material from the middle portion of the lever.
Model 1:

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• It can be seen that by reducing the mass from the model, the stress value is increasing
and for the optimized model i.e. model 2, stress is 1.83 E+04 lb/in2. Comparing this
value with the yield stress for the malleable cast iron i.e. 3.625 E+04 lb/in2, it can be
concluded that the factor of safety is approx. 2 & the final optimized model is acceptable.
Model 2:

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Analysis Project at Butler International Inc.
• Compare different configurations of valves using given point load, moment,
material and boundary conditions
• Software Used: Pro/Mechanica
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