Roshan Gautam

About Roshan Gautam

Mechanical & manufacturing engineer specializing in new product introduction and experimental hardware. I combine Los Alamos National Laboratory high‑voltage systems experience with Zimmer Biomet medical device manufacturing to solve problems in cost, quality, and reliability.At LANL, I worked on 200 kV high‑voltage experimental systems, designing internal structures and supporting electrode calibration for EDM research. At Zimmer Biomet, I lead manufacturing engineering for new orthopedic products, driving cost and scrap reduction through FMEA, FAL, equipment qualification, and process standardization.Selected results:Designed internal structure for a 200 kV high‑voltage system at LANL using SolidWorks; supported calibration and setup for high‑consequence experiments.Delivered a rework process for a nail system at Zimmer Biomet that generated $100K+ in cost savings by reducing material scrap and downtime.Improved dimensional control on bent components by creating a new bend profile measurement methodology, analyzing multiple product orders with statistical techniques.Completed FAL, Gauge R&R, correlation studies, and equipment qualifications for new hip cup and nail system products, enabling launches ahead of schedule.Reduced scrap and improved operator accuracy by implementing visual work aids and standard work on production lines.Led detailed FMEAs for critical polishing operations (nails, clamps, set screws), proactively identifying and mitigating failure modes.I’m interested in roles at U.S. national labs, FFRDCs, and advanced hardware companies where new product introduction, experimental systems, and manufacturing quality intersect.

Experience

1. Manufacturing Engineer

   Zimmer Biomet

   Jun 2024 — Present · Warsaw, IN, US

   Lead manufacturing engineering for new orthopedic products, focusing on new product introduction (NPI), cost and scrap reduction, and robust processes in a regulated medical device environment.1. Design and implement rework processes for nail systems that reduce material scrap and downtime, generating $100K+ in annual cost savings.2. Improve dimensional control of bent components by developing a bend profile measurement methodology, using statistical analysis (PPK, histograms) across multiple product orders.3. Execute FAL (First Article Layout), Gauge R&R, correlation studies, and tool path analysis for new hip cup and nail system products, ensuring quality and compliance and contributing to launches ahead of schedule.4. Lead equipment qualifications (EQ) for new and existing assets, enabling faster ramp‑up and stable production for new product introductions.5. Create visual work aids and standard work instructions for operators, improving accuracy, consistency, and training time on production lines.6. Develop and maintain FMEAs for critical polishing operations on nails, clamps, and set screws, proactively identifying and mitigating process risks.7. Collaborate with cross‑functional teams in design, quality, and operations; recognized with 7 Ignite Awards for production readiness and continuous improvement contributions.

Education

• TAFE NSW

  Bachelor of Engineering - BE, Mechanical Engineering

  2019 — 2021

• The Times secondary school kathmandu

  High School Degree, Science

  2015 — 2017

• Gaynpunja School

  Science

  2013 — 2015

• Valparaiso University

  Bachelor's degree, Mechanical Engineering