Rajeev Kumar

About Rajeev Kumar

Mechanical Design Engineer with hands-on experience in industrial coupling design and powertrain systems at Regal Rexnord and IC engine design, simulation, and VAVE at Cummins Technical Centre India. I specialize in full product development lifecycle: concept design, CAD modeling, FEA simulation, DFM, GD & T, compliant drawings and manufacturing release — across both rotating machinery and internal combustion engine systems.I bring a strong combination of— Multi-domain design depth — coupling systems (jaw, disc, gear, flexible) at Regal Rexnord and engine structural components at Cummins, giving me rare cross-industry perspective in power transmission and powertrain.Simulation-driven design — ANSYS, HyperMesh, Abaqus, ANSA and STAR-CCM+ for structural, fatigue, torsional, and thermal validation — reducing prototype cycles and catching failures early.Cost engineering mindset — hands-on VAVE (Value Analysis / Value Engineering) experience at Cummins driving material and design cost reductions without compromising performance.Structured quality frameworks — DFMEA, FTA, 8D, 5-Why, RCA, Six Sigma, Kaizen, and VSM applied across NPD programs at both organizations.PLM & cross-functional collaboration — managing ECOs, BOMs, and design documentation across design, manufacturing, quality, and supply chain teams.Passionate about building mechanical systems that are reliable, lightweight, cost-effective, and manufacturable at scale. Open to senior design, simulation, or product development roles in industrial machinery, power transmission, automotive, or off-highway powertrain domains.

Experience

1. Design Engineer Ii

   Regal Rexnord

   Jun 2025 — Present · Hyderabad, IN

   Designed and developed industrial coupling assemblies (jaw, disc, gear, and flexible types) using SolidWorks and CATIA — executing tolerance stack-up, GD & T-compliant drawings, and BOM management for supplier and manufacturing release across 8+ product programs.Performed FEA structural and fatigue analysis (ANSYS, HyperMesh, Abaqus) on coupling components under torsional, axial, and angular misalignment loading — cutting physical prototype iterations by 60% and accelerating design validation timelines by an average of 3 build cycles per program.Led DFMEA and FTA reviews at NPD gate checkpoints across 8 product launches, identifying critical failure modes and driving design changes before design freeze — resulting in zero P0 field failures at production release.Applied 8D and 5-Why RCA methodology to resolve 15+ field and customer failure events, implementing corrective design and process actions that reduced repeat warranty incidents by ~40% across affected product lines.Facilitated Kaizen and VSM workshops on coupling assembly lines, eliminating non-value-added steps and implementing DFM changes that reduced assembly cycle time by 2.5 hours per unit — delivering measurable throughput gains across production shifts.Managed 50+ engineering changes and design records through PLM, ensuring revision control and cross-functional sign-off across design, quality, and manufacturing teams.

Education

• DAV Public School Dugda

  Intermediate, Science (PCM)

• Vinoba Bhave University

  B.tech, Mechanical Engineering

• Central Board of Secondary Education

  Matriculation, General

• National Institute of Technology Warangal

  Master of Technology - MTech, Machine design