Karthikeyan Danasagaran

Work History

Work History
Jun 2013 - Present

Asst. Manager

Cummins Filtration
  • Working on new product development and current product development of Liquid filters, head casting, adaptor’s, plastic and drain valve.
  • Working on creating new Change request and Change note using Windchill 10.Also creating metadata for new parts and other documentation.
  • Working on design of casting, machining and plastic components.
  • Working on creating Part and design for new products and current products and updating prints. Working on checking if the design would satisfy the requirement or not.
  • Working on hand calculation for finding the needed parameters in new product design and a product re-design.
  • Working on flow and pressure drop related problem and other calculation relating to filter.
  • Working on new casting and machining parts.
  • Attended team meeting, seminar and product training.
  • Using theory of constraints (TOC) in day to day activity to solve problem in least time with best solution.
  • Working on doing structural and flow related analysis.
  • Working on creating Standard operating procedure for documents for designing a part and testing the design using calculation and other calculator.
Aug 2012 - Dec 2012

Project Engineer-Locomotives

  • Worked on Concept Development and Value Engineering phase for Locomotives for GE. Also working on Cost saving Project’s.
  • Performed a detailed analysis to present all tollgate presentation as per the given guidelines by business to get the required approval at business level.
  • Worked to understand the life cycle and cost analysis of product for each part for the customer.
  • Performed a detailed analysis of product with design engineer to understand the opportunity to remove scheduled / unscheduled frequency or rates for different customer on MSA contracts for GETS.
  • Identified the critical path to prepare the milestone & execute the project milestone accordingly.
  • Performed the cost benefit analysis and present it to risk & principle engineer for their approval.
  • Worked with multifunctional team on problem solving, 7Ways, team meeting and other activates.
  • Worked closely with manufacturing team, sourcing team, current product development team and new product development team.
  • Did design, development in Unigraphics. Also preformed fit form and function.
  • Did product trial and validation with cardboard model and steel structure whenever needed.
Apr 2012 - Jul 2012

Design Engineer

  • Responsible for current product design changes, deviation change & implement the changes for development purpose of Articulated Trucks & Lower Power Train products.
  • Worked on Team Center to initiate ECO for purpose of creating/changing print and releasing them for production purpose. Managing multiple ECO and print modification at the same time.
  • Act as a checker for the prints before been released to Release department.
  • Products design are done on Pro E and using Team center to save them in the Team center server.
  • Also Analyzed the product structure using Pro Mechanica, Fastener Adviser and Bolted joint analysis. Did also free hand calculation to get the rough estimate of the result.
  • Worked with Off shore team in order to get my design and drafting changes work done.
  • Worked on Cost Reduction project to reduce the cost of the purchased component down and standardizing part, common features and changing dimension to make part cost effective.
  • Overviewed Prototype build and testing of Power train parts.
  • Attend weekly Design Review and team meeting to communicate the progress in the project.
  • Worked closely with cross functional team to get pricing of products and provide information and support.
Sep 2011 - Feb 2012

Project Engineer-Packaging

  • Responsible for new product design & development of After Treatment systems & components to meet off-high way emission requirements.
  • Created & managed project plans to align with key VPI program deliverables.
  • Collected, identified, clarified, & tracked status of technical deliverables to meet customer requirements. Design requirement were mainly got from technical deliverables and from other standards.
  • Design was done in Pro E wildfire 4 and most of the parts used were sheet metal.
  • Information from Technical Profile, Engineering Standard Work and iDFMA and tracked using Design Verification Plan and Report (DVP&R) which is a report used to task as a line item and status of the with plan and actual.
  • Design validation was done by using the Engineering Standard Work and limits set by Technical Profile deliverables.
  • Identified key design issue and addressed them to mitigated program & product risk.
  • Resolved & closed product & program issues relating to Packaging design.
  • Managed & effectively communicated project status to cross functional team and program lead.
  • Initiated & coordinated technical support work.
  • Leaded Concept and Design phase of packaging and helped cross functional design and development reviews.
  • Currently working on prints work in L phase. Acting as a Design checking and verification Engineer.
  • Support technical & program reviews of my core team.
  • Document intellectual property generated as part of design process.
  • Created ECR, ECO, Bill of material (BOM), part number and worked in print release process.
  • Communicated with Off shore team and lead a team of 4 member and got my work done.
  • Planed the entire plan of each phase mainly design and executed and tracked the project status using MS project.
Mar 2011 - Aug 2011

Mechanical Design Engineer

  • Responsible for designing, detailing and assembly of fixture in Pro E Wildfire 4 for Caterpillar and John Deere parts.
  • Used PTC Wind Chill to manage, store, and modify Pro E file.
  • Did concept design, then used top down approach for design and part modeled and assembled the product.
  • Reviewed product and process requirements and standards.
  • Communicated with client gather requirement and with offshore team guiding leading the project.
Jan 2010 - Aug 2010

Fluid Dynamics Research Center IIT

Fluid Dynamics Research Center IIT
  • Responsible for designing new exhaust HVAC duct from starch and integrated it with the wind turbine exhaust
  • Used Sheet Metal component of Pro E to design the new HVAC duct and exhaust outlet of Wind turbine.
  • Fabricated the HVAC duct and the wind turbine exhaust and assembled them.
Jan 2009 - Aug 2009


  • Responsible for working on tool brake rate , speed of cut, depth of cut and feed rate of CNC machine
  • Installed sensors and mike to record the vibration and noise of tool breakage.
  • Successfully installed and reduced and improved the efficiency and reduced the tool breakage rate.



2006 - 2007

New Product Developer & Production Engineer


Served as New Product Developer & Test Engineer for the Production Engineering Department in the Research and Development division of SCL.  Handled the new product development including:


  • Marked and studied customers’ drawings and met the customers’ specific requirements and conducted technical reviews and weekly project reviews with customers.
  • Performed process planning for new products including selection of machines, design and development of fixtures, tools, gauges, washing machine and leak test rigs.
  • Handled cell formation for new products with all facilities and ensured the ramp-up production was on-time.
  • Prepared project reports, calculated Takt time and cycle time for all projects.
  • Created assembly drawing and including Bill of Materials (BoM) for tools, fixtures and gauges drawing using Pro E , Solid Works and AutoCAD with detailed part diagrams 2D/3D of the individual parts and also fabricated them. Used BoM to select and specify the material property and number of parts in the 2D draft. I used Geometric Dimensions and Tolerances (G&T) in the drawing and prepared the blue print of the product.
  • Experience in reviewing the design drawing and testing them for critical dimensions, errors and reliability.
  • Selected tools and gauges based on the need then modified it as per requirement.
  • Created cells for product with the number of CNC and special purpose machines, gauge checking equipment, leak test machines and final assembly tables.
  • Performed CNC programming and machining of the product checking for  quality and reliability using gauges, CMM machine and profile projectors
  • Experience using SAP to procure and maintain inventory. Created purchase order using SAP. Experience with SAP Production Planning and Material Management modules.
  • Completed test components of three Prototype samples (100 each) with the desired results and assembled with the other components. Inspected sampled before sending it to them client.
  • Learned and implemented Lean manufacturing, Kanban process in the production line.
  • Prepared documentation on PPAP (Part Production and Approval Process) manufacturing drawing, production process and handed over manual for production.
  • Tested the component for reliability using disruptive and non-distortive and simulation software.
  • Used Six Sigma and DMAIC methodology in the manufacturing line to control the number of defects.
  • Interacted with multiple vendors and contractors to set goal and delicate duties and get my work done. I also collaborate and contribute effectively in a cross-functional team environment, including leading design team meeting and also participated in other design review meeting too.
  • Troubleshooted problem during the drawing, assembly and manufacturing.
  • Supervised and trained other Junior Engineer and GET.


Aug 2007 - May 2010


Illinois Institute of Technology IIT
Aug 2002 - May 2006


Anna University



Production Line