# Joshy T. > Sr. Plastics Tooling Engineer (mechanical Tooling, molding process, mechanical assembly) at Fiserv Location: San Francisco Bay Area, United States Profile: https://flows.cv/joshy Years of experience in simulation, development and qualification of injection molded parts, MIM and stamped parts in different industry sectors. Proficient in supplier development, supplier quality, lean tools based process improvements. ## Work Experience ### Sr Plastics Tooling (Mechanical) @ Fiserv Jan 2025 – Present • ​Led the DFM, DFA review and sign-off activities on components and assembly fixtures with ODM. • Made planned efforts to improve the GD&T usage and call outs in the right way on the 2D prints coming from the ODM. • ​Executed molding press spec compatibility verification and developed a press independent process set up for transferred molds. • Planned for next year's budgets to bring simulation tools like Autodesk Insight/ Moldex3D in-house. • Track the timelines for on-time executions and to be able to meet key milestones by conducting regular meetings and minutes with external supply sources using APQP and PPAP processes. ### Principal Product design (Molding & Field Application) Engineer @ LUXSHARE-ICT Jan 2023 – Jan 2024 • ​Led the molding project development engagement for NPI at the customer as well as with factory development team by identifying potential concerns and plans to mitigate those. • ​Assisted in assembly, functional test, ORT related FACA issues on the module where customer concerns arise at build phases working closely with R&D and factory in China. • ​Exposed and experienced in the DFM review and development of reel-to-reel insert molding with final product tolerance range +/- 0.020mm. • ​Developed initial concepts for painting, anodizing, and sand blasting on plastic and MIM parts. • ​Supported the design of measurement fixtures based on GD&T interpretation and provided input into the MSOP to be able to better assess the deviation reports for next steps. • ​Carried out DOEs to complete the RCCA with curing parameters for different types of glues (UV and oven cured) on ORT assembly issues. ### Principal Tooling and Molding Engineer @ Johnson & Johnson Jan 2019 – Jan 2023 • ​Reviewed tool designs and kicked off 60+ injection molds, and with help from DOE corner studies, completed the IQ, OQ, and PQ process validations. • ​Perform the hands-on fill-pack and cool-warp simulations (MFA) on new part geometries to identify molding defects, inefficiencies, verify compatibility of material grades with the gate locations. • ​Audited mold/molding sources to assess their capability and know-how to source injection molds for various thermoplastics, TPU, TPE, and MIM parts and add shortlisted ones to the AVL. • ​Led the process validation sign-off during IQ, OQ, and PQ validations on molds based on Minitab/JMP data compiling. • After identifying the nominal process utilized the process capability data, Gage R&R, inspection criteria at IQC/OQC to better manage quality of incoming parts. • ​Led the simplification of part design geometries to simplify the tooling complexity for both new and EC releases in the sustaining. • ​Supported procurement with tooling agreement details that include a short version of tooling technical standards (SPI) for molds. • ​Supported development and debugging MIM and micro-molding components with deviations. • ​Utilizing the data collected on yield loss over time, I have derived RCCA efforts to enhance productivity. ### Plastic Tooling & Process Engineer @ Apple Jan 2014 – Jan 2019 • ​Setting the industrial design (ID) expectations as goals continually advanced the tool design and ancillary fixtures to higher standards. • ​Supported Product design (PD) on geometries and GSM on the involved cost. • ​Reviewed the DFM/DFA, assessed alternative paths, and potential pitfalls. • ​Hands on process development and debug at vendor molding presses in Asia for a wide variety of resins. • ​Experienced in turning around small to medium size contract manufacturers on improved product quality and method of documentation. • ​Led on time ramp readiness and continuous productivity improvements for plastics manufacturing and FATP site. • ​Established the concept of ancillary fixture designs as part of DFM to review and sign-off. ### Senior staff Plastics Engineer @ Continental Jan 2004 – Jan 2014 • ​Optimized plastic component designs and created mold design concepts using data from hands on mold flow simulations results. • ​Mentored product design community for potential changes to various part design geometries based on feasibility assessment, which in turn reduced the cost and improved yields. • ​Lead the efforts to identify, audit, and develop mold-building sources for interior parts. Yields and cost reductions were up by ~15% compared with tools bought from sources that were not audited/approved by ​SME. • ​Developed and debugged optical components such as Lens (PC), light pipes (PMMA) for speedometer and ADAS displays. • ​Introduced capability study data verification, scientific processing using DOE and SPC data, prior to tooling transfer. • ​Initiated and reviewed supplier mold tool quotes, finalized tool specifications, molding press spec compatibility, and cost justifications. • ​Familiar with RCHM (Vario-therm) IMD, IML, hot foil, pad print, laser etch, chrome plating, painting, hard coating, vibration, ultrasonic and laser welding, gas assist molding and Mucell technology. • ​Familiar with processing of PP, ABS, PMMA, PC, PBT, PPO, PA6/66, PEEK, POM resins. ### Tooling Engineer (Plastics, metal) @ FCI AUTOMOTIVE NORTH AMERICA A DIVISION OF FCI USA INC Jan 1998 – Jan 2004 • Familiar with molding and testing engineering grade resins such as PBT, PA6, PA66, and POM. • Carried out progressive die design reviews for terminal contacts. Used DFMEA and PFMEA. • Supported quotes, site audits, timing schedule, run at rates, and cycle time monitoring. • Reviewed mold designs, mold flow analysis and potential hot runner applications to the injection mold projects with follow-ups and visits to facilities. • Developed and debugged molding process cycles applying scientific molding principles, cavity pressure sensors and melt flipper technologies. • Involved in the strip lay-out, build and try-out of progressive stamping dies for various wire terminals. • Supported the development of test block fixtures for wire harness testing (continuity, impedance, hi-pot) and crimp dies for wire terminations, crimp validations such as pull and corrosion testing. ## Education ### Mechanical Engineering The University of Texas at El Paso ### Advanced Tool design University of Wisconsin-Milwaukee ## Contact & Social - LinkedIn: https://linkedin.com/in/joshy-t --- Source: https://flows.cv/joshy JSON Resume: https://flows.cv/joshy/resume.json Last updated: 2026-04-13