1. Continued
Varun Kumar
245 Mosspoint circle, Apt. 22, Spartanburg, SC - 29303
Cell: 864-986-5405
Email: kumar3@g.clemson.edu
Career Summary
An ingenious and self-motivated mechanical engineer with three years of experience in automotive
engine design and product development, seeking a full time position as a design engineer in a leading
environment. An ardent follower of first time right and every time right ideology, also known for
applying cost effective and methodological approach for new product designs to meet functional,
manufacturing and customer requirements.
Education
Master of Science in Mechanical Engineering
Specialization: Design and Manufacturing
Clemson University, Clemson, SC, USA
August 2016
GPA: 3.90/4.00
Bachelor of Mechanical Engineering June 2011
Birla Institute of Technology, Mesra, Ranchi, India GPA: 8.39/10.00
Work Experience
ZF Transmissions LLC, Gray Court, SC Oct 2016 – Dec 2016
Intern, Advanced Problem Solving and Support
 Identifying types and locations for all waste receptacles in ZF Gray Court facility for initial Waste
Management strategy assessment.
 Identifying the root cause for height measurement issue using Red-X problem solving strategy.
Mahindra and Mahindra Ltd. (Technology Product Development) Aug 2011 – July 2014
Assistant Manager, Engine Design and Development (Automotive Sector)
Formulated innovative and robust design solutions for diesel engine components and assemblies using
Unigraphics. Coordinated with suppliers and manufacturing teams for implementation of development
projects and alleviating manufacturing concerns. Other tasks included competitor benchmarking,
redressal of quality and field concerns, development of product requirements for suppliers, design and
tolerance stack-up calculations, technical documentation and engineering BOM preparation, packaging
study, engineering change management, drawing release and revisions, leading DFMEA, pre-ECN and
design review sessions, preliminary FEA analysis of new designs, leading value engineering and cost
reduction projects, drive prototype development by coordinating prototype build, testing and validation
activities, provide support to calibration and vehicle teams for respective applications.
 Eliminated the requirement for a separate fuel pump camshaft by integrating cam lobe on main
camshaft of a push-rod type engine.
 Achieved 10% cost reduction in an existing connecting rod assembly through design optimization
and product commonization.
 Accomplished 2% reduction in total cost of an existing engine through value engineering and
adoption of new fuel injection system from alternate supplier.
 Optimized the design of an existing crankshaft to reduce its forging mass by 1.2 Kg and increase
torsional stiffness by 10%.
 Devised a new 'spacer' concept for mounting speed sensor on existing flywheel housing to elude
the need for a new housing development.
Technical Skills
Unigraphics (NX) 8.0 GT-Power Teamcenter Enterprise Quality Assurance
Pro-E/CREO QFD Minitab, R, PHP, SQL ANSYS
MATLAB DFMEA Finite Element Analysis Design for X
SolidWorks GD&T Root Cause Analysis APQP

2. Varun Kumar 2
Industrial Projects
Design and development of a new 2.5 L diesel engine with new fuel Dec 2011 – May 2014
injection system
The project task included re-design of an existing common rail engine with a new Fuel Injection system
comprising of new common rails, injectors, fuel metering unit and fuel pump. A significant amount of
value engineering was also involved. Other tasks included prototype development, validation and
testing of prototype engines and new components. Major accomplishments include design of injector
clamps, fuel return layout, air intake manifold, high pressure pipes and fuel pump camshaft housing.
All project deadlines were met, and project was awarded as best in value engineering category.
Design of a high power engine for Light Commercial Vehicle application Aug 2013 – July 2014
The project included development of a new engine based on an existing engine family with enhanced
power output for use in a Light commercial vehicle. Design tasks included development of new
connecting rod, crankshaft, camshaft with integrated Fuel Pump driving cam, integration of Fuel Pump
into crankcase, design and development of integrated oil and vacuum pump unit.
Value engineering and cost reduction projects
 Design, development and market implementation of a weight optimized connecting rod for an
existing engine platform (in production).
 Design and development of sintered bearing caps for an existing engine (in validation).
 Design and development of a weight optimized crankshaft for existing engine (in validation).
 Development of a new Aluminum body oil pump for an existing engine (in validation).
Academic projects
Intake runner design for Miata 1.6 L engine Aug 2015 – Dec 2015
The objective of this project was to design an intake runner for 1.6 L Miata engine to maximize average
IMEP between 2000 and 5000 RPM. To achieve this, the engine was modeled in GT Power using the
dimensions and parameters of existing components. Thereafter, a CAD model for the new intake was
prepared and included in the simulation model. The software model was used to optimize the length
and diameter of intake runner with the objective of maximizing volumetric efficiency. Based on
optimization results, final CAD model and prototype was prepared which was tested on the engine.
Engine was calibrated to maximize average IMEP over the operating RPM range. The design produced
the best average IMEP results in class.
Optimization of EA-81 Flywheel design Aug 2014 – Dec 2014
The objective of this project was to optimize the design of existing EA – 81 flywheel design. In
particular, the project requirement was to couple a simulation software (ANSYS) with an optimizer so
that concurrent design optimization and FEA evaluation can be achieved. Burst speed simulation was
used for obtaining the maximum stress generated in the flywheel which was used as a constraint for the
optimizer. Maximizing moment of inertia of the flywheel while minimizing its mass was chosen as the
objective function for the optimization routine. The optimized design had approximately 8% higher
moment of inertia and a 4% reduced mass as compared to original design.
Other projects
 Machining process simulation and manufacturing cost optimization of an optical mount.
 Investigation of casting process for new Aluminum oil pump cover plate.
 Effect of end load and tool speed on torque and temperature of flow screw drilling: an experimental
study.
Achievements and Extra Curricular Activities
 Qualified in the Regional Mathematics Olympiad and Aryabhatta Mathematics Olympiad.
 Qualified in IITJEE-2007 merit list and secured 99% percentile in All India Engineering Exam.
 Ranked amongst the top three students in class throughout school curriculum.
 Captain of the Institute Cricket team at BIT Mesra, Ranchi.
 Winner of 17th
and 19th
Chetan-Devraj Inter University cricket tournament. Also adjudged the best
player in 19th
edition.
 Runners up in volleyball at sports fest ‘Spardha’ organized by IIT Kharagpur.