Aadisesh Nallappa Sampath

● Led high-voltage battery pack development for storage, locomotives, and mining applications ● Contributed to the planning, coordination, and execution of test plans within New Product and New Technology Programs ● Conducted system-level and component level validation activities at Caterpillar’s internal facilities: BMS software verification, Duty cycle assessments, durability testing , Shake table testing and EMC testing ● Performed compliance-based testing at external facilities, addressing mechanical abuse, thermal abuse, and environmental tests following EC 62619, UL 2580, and UN 38.3 standards ● Managed supplier selection and RFQ process for test equipment and prototype components to meet functional test schedules ● Oversaw project management by facilitating weekly meetings with internal teams and test laboratories to review data, ensure timeline compliance, resolve issues, and provide ongoing support. ● Conducted root cause analysis on tested components, providing corrective feedback to engineers to avoid failures. ● Supported prototype builds, overseeing instrumentation installation, supplier coordination, and end-of-line testing ● Performed basic electrical troubleshooting on low voltage systems by referring to schematics and measurement equipment. ● Developed automated data analysis scripts and reduced turnaround time by 70% ● Participated in development and review of FMEA documentation in coordination with systems and compliance teams ● Provided regular product validation status reports to chief engineers and senior leaderships

Underbody, Chassis and Suspension Systems Instrument Panel, Dashboard and Center Console Systems • VAVE responsibilities to improve customer product cost and provide engineering recommendations • Worked closed with electrical teams for better efficiency in the integration of mechanical and electrical components • Analyzed teardown parts for standout features by benchmarking with competitor vehicles in SUVs, Pickup trucks and electric vehicles segment (MachE, Tesla ModelY and ID.4) • Reviewed observations with subject matter experts to determine potential cost reduction opportunities. • Worked on building and maintaining cost out ideas and ensuring each idea is being rationalized in a timely manner. • Worked with larger competency teams globally (mechanical, electrical, manufacturing engineering teams) to gain insight to cost opportunities which may be applied to customer products and also rationalize existing opportunities by saving assembly time. • Led management of cross functional VAVE events / review sessions to report out potential, actionable changes to design, material selection, complexity and process changes that lead to cost improvements with customer vehicles, • Part of the North American VAVE team, working in alignment with offshore teams following overall operations strategy of Digital Twin Benchmarking. • Serve customers in the North America and China market and work towards their cost targets.

• Responsible for the Design & release process of transmission components: gears, carriers, pinion shafts and other planetary gear components. • Worked with systems engineering team, Ford manufacturing plants and component suppliers to meet program requirements for quality, cost, weight, durability and NVH. • Work with CAD/CAE, manufacturing engineering and suppliers to deliver optimized designs to solve manufacturing and assembly issues after identifying feasibility. • Raised concerns and alerts on Ford’s worldwide engineering release system for components and assemblies to process engineering change requests, mainly involving drawing revision and process improvement. • Lead design reviews, change control meetings and TVM meetings. Prioritize and tracked open issues every week, followed release/change process with proper documentation. • Actively worked on implementing cost reduction ideas after cross functional team reviews to find requirements for testing and trial validations. Set design verification plans to ensure safety and robustness of design changes. • Cater to the needs of Ford’s other global locations – China and Mexico. • Actively worked with suppliers to support program deliverables as related to PPAP and APQP • Analyze warranty/test hardware to identify root cause of failure and define corrective actions using 8D tools/methods • Develop, track and update engineering quality documents e.g. DFMEA, DVP&R, P-Diagram, Boundary Diagram

• Testing of engines on dyno according to customer’s test cases to get parameter plots and check component durability. • Resolved technical issues – rework of parts at supplier, engine build issues, failure during testing and validation. • Worked with the testing and development teams to cater engine testing needs. Helped in solving issues related to emissions, leakages and component failure. • Work involved on a 12 cylinder, 2 stroke opposed piston diesel engine with piston scuff, carbon deposit and other issues. • Use data acquired from engine test runs, sorted them based on loads, engine speed, hardware change etc, extensively using Excel. Performed root cause analysis for issues obtained from the customer data. • Presented the progress and reviewed open items during weekly review meetings. Used basic engineering calculations to create concept 3D CAD models. Used decision matrix to find the best solution. • Pre CAE analysis of new models using Creo simulate to check if design is safe in terms of stresses and displacements. Pass on the analysis package to the CAE team with if further finite element analysis is needed. • Assisted in the procurement of components according to the quality standards and coordinated prototype builds. Checked for fit form and function. Order rework and optimize design to solve design issues and avoid scrap. • DFMEA, Bill of material correction and verification, assisted with procuring parts for building prototypes. • Hands on experience working with technicians on teardowns, assembly and other fabrication process. • Benchmark components and present to customers, ideas to improve cost, design and performance. • Project proposal to customers involving preparation of design checklist to install sensors on inlet manifold.

• Estimated the prices of valves and dampers for different sizes and applications. • Created standardized prices for pneumatic and manually operated valves of sizes ranging from 200mm - 2600mm, thus reducing lead time to reduce customer quotations. • Collaborated with design and supply chain departments to ensure optimum requirements and budget.

• Calibrated measuring instruments and inspected samples demanding high accuracy (bearings). • Conducted material tests to find micro-structure, hardness and other metallurgical properties. • Assisted with assembly of lathe's and machining operations in HMC's and VMC's

• Responsible for the procurement and product development of one cylinder and two-cylinder diesel engines through proto and tooled route by following APQP. • Coordinated with internal CAD team and suppliers to build prototypes needed for internal testings/validations, verified and ensured design changes at the product introduction stage. • Directed the suppliers with product modifications in prototypes as per test results and root cause analysis. • Visited supplier facility to evaluate tooling, production process and also ensure if FMEA is followed. • Assisted in strategically sourcing engine components accounting the prices, delivery and quality of the supplier. • Coordinated with other departments and initiated engineering change requests for required changes in BOM. • Assisted the production team along with the CAD team to build prototype engines. • Generated purchase orders, initiated payments and handled outside processing of components with proper documentation. • Performed benchmarking and tear down analysis of competitive engine parts and organized departmental workshops to collect VA/VE ideas. • Analyzed the collected VA/VE data for design change, material change, manufacturing process improvement and cost reduction. • Tested, finalized and pre-implemented engineering ideas ensuring annual savings of more than $6000 (3,80,000 Indian Rupees) • Organized weekly team meeting with presentations for tracking projects and assisted in resolution of issues

Coursework opted - Automotive Powertrains, Powertrain NVH of Electrified Vehicles, Finite Element Methods, Electric Aspects of Hybrid Vehicles and Acoustics - Noise Control