Open to new opportunities — relocating immediately
// Sr. Mechanical Engineer — 7+ Years · NPI · Consumer Products · Medical Devices · Process Engineering
Aananthan Mariappan
Systems Architect · Robotics · NPI · Manufacturing
From consumer products to medical devices — designing, launching, and optimizing manufacturing systems end-to-end. Turning engineering problems into measurable results across NPI, process, and automation.
Sr. Mechanical Engineer leading end-to-end system design, process engineering, and automation strategy — driving cross-functional teams from concept through production-ready launch.
Led end-to-end $100M+ CapEx project — AutoCAD layout, SolidWorks fixtures, Flexsim simulation, vendor RFQ, ROI modeling. Ramped throughput 10% monthly.
Cut system downtime from 18% → 2%, increased OEE by 8.5%. Saved $1.4M labor; achieved $6.4M positive cash flow by year 3.
Built AI-powered Python optimization tool for battery utilization, eliminating 10% peak downtime.
Piloted safety systems ($1.5M CapEx) across 12 warehouses — achieved 11% reduction in incidents.
AutoCADSolidWorksFlexsimPython/AIpFMEAVSMMES
Elan Technologies
Boston, MA
NOV 2023 — JAN 2025
Consultant Mech. Engineer II
Led end-to-end NPI projects from concept to launch, driving FMEA/DMAIC continuous improvement and process capability studies.
Designed tools, jigs & fixtures (SolidWorks, DFM/DFA); integrated camera vision to reduce false scrap by 20%.
Current building had throughput constraint due to mechanical failure & system design. Led a full DMAIC-driven rebuild targeting two problem buckets: Machine & Throughput and Labor, Safety, Process, Ergonomics.
Process optimization → 3 touch points vs 5–7 → increased process rate/cycle time
Flexible MHE → handles cases up to 50lb, increased storage cube by 21%
Tracking system (Jam Cam, MES, SDEN) → 20% reduced downtime
100% safety hazard eliminated, 15% reduction in labor traffic incidents
DMAICFishboneVSMFlexsimSolidWorksMESCapEx/OpEx
Industrial Engineering
5%
Battery & Layout Optimization Tool
All sites used 100% hydrogen fuel PITs, requiring dedicated refueling time — causing downtime across all zones. Proposed converting dock PITs to Li-ion with opportunity charging.
Eliminated downtime at the dock entirely
Removed need for additional PITs and labor at dock
AI-powered Python script to optimize sub-system location → 5% layout efficiency gain
Increased man vs machine integration by 4%
PythonAI/MLAutoCADNPV Analysis
Warehouse Architecture
22%
One→Two-Sided Building Process Flow
One-sided flow caused 20% increased traffic at IB & OB junction, 20% reduced PIT process rate, and high-density labor distribution creating egress risk with 165 AAs at dock.
Installed lift gates at every PIT/Ped zone → incidents reduced 4 → 1 per day
PIT process rate increased 17 → 22/25 Pph
Labor reduced from 165 → 85 AA at each dock area
AutoCAD LayoutVSMErgoOSHA
Vizgen · NPI
32%
Manual → Semi-Automated Production Line
Designed the entire assembly/production line from phase 0→1 to eliminate high scrap rate on a fluid distribution system. Used FMEA to rank failure modes by RPN — highest severity: tool deformation, pressure rupture, temperature variation.
Designed automated fluid distribution system in SolidWorks
Reduced scrap to 5% from baseline via semi-automated filling station
Built PowerBI + SQL dashboard → 32% reduction in operational errors
SolidWorksFMEA/RPNIQ/OQ/PQPowerBISQL
Insulet · Medical Device
10%
Omnipod Insulin Pump — Mfg Failure Analysis
Worked at Insulet to solve long-term manufacturing failures on the Omnipod — a wearable insulin pump for diabetic patients using continuous glucose monitoring.
Reverse-engineered failure modes via lean test runs + SolidWorks/Creo design analysis
BOM analysis in NetSuite ERP → identified root causes of high-volume daily rejects
Standardized SOPs → prevented 2,500 daily rejects
Increased production capacity by 10%
SolidWorksCreoRCANetSuite ERPPPAP
Elan · Covid Response
20%
Ventilator Line Semi-Automation
Worked on assembly process of ventilators during peak COVID-19, tasked with semi-automating a manual line due to critical worker shortage.
VSM → Process rate analysis → Product design → Control failure modes
Streamlined data flow and process flow for continuous monitoring
Reduced false scrap by 20% via camera vision integration
VSMDFM/DFACamera VisionMES
NPI · Concept → Launch
0→1
Hair Dryer NPI Manufacturing Line
Led end-to-end NPI manufacturing line for a hair dryer product — from sub-assembly design through mass production launch.
Led design of sub-assemblies (PV1, PV2… PVx iterations)
DFA/DFM to simplify assembly, finalized for manufacturability
Spearheaded EVT, DVT, PVT testing, validation and qualification
RFQ with vendors, CapEx/OpEx/NPV finance sign-off, leadership review
SolidWorksDFM/DFAEVT/DVT/PVTRFQNPI Gateway
NPI · Medical Device
0→1
Peristaltic Pump NPI Manufacturing Line
Led end-to-end NPI for a peristaltic pump (Pump Head, Roller Assembly, Pump Tube, Cover) — from concept design to full production launch for a medical-grade fluid delivery application.
Designed sub-assemblies through multiple prototype iterations
Full DFA/DFM analysis for manufacturing simplification
Authored leadership review documents for CapEx/OpEx approval
Cross-functional launch execution with continuous monitoring post-launch
SolidWorks3D PrintingcGMPIQ/OQ/PQRFQ
// Methodology
NPI Process Flow
Worked on NPI products from 0→1 across medical devices, consumer electronics, and industrial automation. Each project followed this gate-based framework — requiring deep collaboration across design, data, process, safety, ergonomics, supply chain, and quality.
PVT → PFMEA & control plan → IQ/OQ/PQ → Supply chain & QA readiness
›
GATE 5
Production Launch
SOP → Mass production → Ramp-up → Yield & cost improvement cycle
// 3D Design Portfolio
SolidWorks CAD Models
18 pages of SolidWorks design work — FEA analysis, fluid simulation, CNC CAM, aerospace assemblies, medical devices, and surface modeling. See them all in the Design tab.
Hands-on SolidWorks expertise across FEA simulation, fluid dynamics, CNC CAM programming, surface modeling, and complex assemblies. Click any image to view full size.