Koushik K.

Experience

• Mechanical Design Engineer - Level 2 Rockwell Automation/Allen-Bradley · Full-time Oct 2023 – Present 2 yrs 2 mos Bengaluru, KA, India -NPI Project Low Voltage Drive, End-to-End Mechanical Design development in Creo, covering concept generation and detailed engineering. Managed Windchill data and performed BOM risk analysis to support product resiliency efforts.
  
  - Designed sheet metal enclosures, busbars, and cable/harness routing, mounting methods and space utilization for reliable packaging of electro-mechanical components.
  
  - POC, Qualification Test & Pilot Build, by coordinating material readiness, placing shopping carts, reviewing assembly sequences, and facilitating PPAP approval discussions with cross-functional teams.
  
  - Led End-of-Life and Last Time Buy projects, validating drop-in replacements for MCCBs, hardware components, fans, gaskets, and other off-the-shelf parts, preparing detailed design considerations, and aligning stakeholders on implementation strategies.
  
  - Delivered replacement kit solutions (DC Capacitor Kits, FPGA Kits, MCCB Kits, Spare Fan Kits) for drive cabinets and power modules, ensuring compatibility and ease of integration.
  
  - Executed continuation engineering by resolving customer complaints, production issues, and quality anomalies; updating designs/BOMs, processing/reviewing Engineering Change Management, conducting design reviews, updating publications, and reviewing PPAP/tolerance stack-ups for fitment feasibility.
  
  - Led Eco-Design Sustainability (ESPR) compliance by collaborating with product compliance teams to compile test reports, energy efficiency data, and regulatory nameplate corrections.
  
  - Trained and mentored new engineers, accelerating onboarding and enabling faster integration into active projects.
• Associate Design Engineer inGO Electric · Full-time Jul 2023 – Sep 2023 2 mos Bengaluru, KA, India - Facilitated mechanical design of electric kick scooters, covering the full NPI cycle from concept generation to prototyping and final release.
  - Collaborated with industrial designers to translate concepts into manufacturable designs that balanced aesthetics and functionality, while also conducting market and competitor studies to benchmark features, cost, and performance.
  - Designed sheet metal, machined, and plastic components in SolidWorks, applying DFM/DFA, GD&T, and tolerance stack-up analysis to ensure manufacturability and fit.
  - Assisted with component sourcing, BOM creation, supplier negotiations, and cost-optimization activities.
  - Prepared engineering documentation (drawings, specifications, design reports) and ensured compliance with design standards and quality processes.
  - Coordinated with suppliers for prototype builds, PPAP readiness, and manufacturability feedback.
  - Contributed to continuous improvement initiatives, reducing design iterations and accelerating time-to-market