Arjun Ballal K.

About Arjun Ballal K.

Innovative Engineer with a passion for Product Design, Engineering, and Sustainability with expertise in Dimensional Engineering, Design For Manufacturing, and Mass Production. I was involved in full-cycle Dimensional Engineering from sketchbook to the launch of Rivian R1 products (R1T and R1S) being a bridge between the Design Studio, Perceived Quality, Product Design, Manufacturing Engineering, and Manufacturing on the below products.** Battery ** Body ( Stampings, Exteriors, Interiors, etc.)** ADAS ( End of line calibration Dimensional inputs to design)** Drive unit ( Overall system-level Design For Manufacturing inputs to design)** Perceived Quality (Interiors and Exteriors)I’m currently responsible to -** Lead Dimensional feedback to R2 Design based on R1 Design learnings and cascade critical Dimensional inputs in design like Datum strategy, slip planes, design gaps, equipment float, critical tolerances, and design enablers to have Gap and Flush DVA results closer to Perceived Quality targets, minimize Dimensional issues during launch.** Work, guide the Dimensional Team on complicated Dimensional Studies and highlight the dimensional risks involved in the product design along with potential solutions to improve it** Prepare technical training materials materials on various dimensional aspects to help product, cross functional teamsMajor Accomplishments Completed 7 years with Rivian, 5 years as a Staff Manufacturing Engineer ** Design For Manufacturing (DFM) guidelines for the Rivian Product team. These guidelines will help Rivian\'s Product Engineers better understand how to design a product for mass production to enable a smooth product launch from a dimensional aspect ** GD & T training material, DVA training and 3DCS training sessions for the Product and Dimensional Engineering teams at Rivian ** Dimensional engineering is one of the major enablers for the successful product launch, also the right tolerances is the key to optimize cost of the product. These training sessions will add a huge value in upskilling cross-functional teams on dimensional aspects and incorporating them into product design. Ford Employee of the Month March 2018 for the ability to adapt to Ford expectationsTaeguTec Star performer of the Q4, 2015

Experience

1. Staff Manufacturing Engineer

   Rivian

   Nov 2020 — Present · Plymouth, MI, US

   Lead Dimensional feedback to R2 based on R1 learnings and cascade critical Dimensional inputs in design like Datum strategy, slip planes, design gaps, equipment float, critical tolerances, and design enablers like local embossed features to minimize Dimensional issues during launch. Development of standards for DFM clearance guidelines to incorporate them in design Development of tutorials on Dimensional variation analysis - Basics and advanced sessions for internal and cross-functional engineering teams covering how to perform 1D tolerance stacks, and 3DCS tolerance stacks, Using measurement data to perform root cause analysis and feedback to the DVA model to help arrive at a decision. Development of standards for DFM machining guidelines, training material on plastics tolerances, usage of DIN standardsLead Dimensional product integration studies and highlight risks like Hood to Fender, Fender Door Flushness, Lift-gate-to-spoiler flushness which is critical for wind noise/ Performance, etc. I was involved in full-cycle product development from sketchbook to launch of Rivian R1 products (R1T and R1S) being a bridge between Design studio, Perceived Quality, Product Design, Manufacturing Engineering, and Manufacturing. Provide Dimensional Variation Analysis (DVA) to design studio and perceived quality teamProvide Design for manufacturing feedback on Dimensional aspect, Datum strategy, GD & T, and measurement points like Statistical process control (SPC) and capability points (CP) which are critical for mass productionProvide Equipment DVA studies to support Equipment design for mass production and Dimensional requirements for Factory Acceptance Tests like G R&R requirements in RFQ Review measurement data and feedback to the initial DVA study to perform root cause analysis Guide the team on DVA studies, run complex DVA simulations, and share Dimensional DFM learnings with internal and cross-functional teams to have a smoother R2 launch

Education

• University of Michigan - Rackham Graduate School

  Master’s Degree, Mechnaical Engineering

  2016 — 2017