# Kapil Ayyawar > Mechanical Engineer | MS | MBA | Six Sigma, Product Development Location: San Jose, California, United States Profile: https://flows.cv/kapilayyawar As a Manager of R&D Mechanical Engineering at Advantest, I lead a team of engineers to design and develop innovative products for the semiconductor testing industry. I have over 16 years of experience in mechanical engineering, spanning various sectors such as appliances, automotive, and industrial equipment. My core competencies include product development, process improvement, problem solving, and project management. I have a strong technical background in CAD, CFD, FEA, GD&T, and Six Sigma, as well as a solid business foundation with an MBA from the University of Illinois at Urbana-Champaign. I am passionate about bringing concepts to market, collaborating with cross-functional stakeholders, and delivering value to customers. ## Work Experience ### Founding Engineer @ Sphinx Jan 2026 – Present ### Lead Mechanical Engineer @ Mill Jan 2025 – Jan 2026 | United States ### Manager, R&D Mechanical Engineering @ Advantest Jan 2022 – Jan 2023 | San Jose, California, United States ### Senior Engineer @ Whirlpool Corporation Jan 2016 – Jan 2022 | Benton Harbor, Michigan, United States ### Lead Design Engineer @ JB Radiator Specialties Jan 2016 – Jan 2016 | Sacramento, California Area Lead Design Engineers to meet workload and Product due dates, checked drawings for GD&T & Stack up to meet production & cost requirements. Designed Heat Exchangers for Engine cooler, Charger Air cooler, Oil cooler, Fuel cooler for Various Engines, Powertrains, & Battery Modules. Performed CFD analysis and mathematical modelling to determine size of radiator core Collaborated with OEM’s to meet timeline and meet IQA (installation quality audits) requirements. ### Project Engineer @ REV Group, Inc Jan 2013 – Jan 2016 | Longview, Texas Area • Re-designed Laymor 3-Wheel Sweeper (SM300) to meet 2014 EPA Standards by Reducing Horse Power consumption by 28% and 7% Cost Reduction. • Designed Schematics and Manifold block for Hydraulic applications. • Conducted Data Acquisition of Hydraulic, Defined accurate load cases based on data. • Created and Maintained DFMEA (Design Failure mode and Effect Analysis) on various components. • Created Design Verification Plan and Report (DVP&R) for Product & Components. • Analyzed Truck Components Finite Element analysis (FEA) using FEMAP Nastran for static and body Loads. • Creation and Maintenance of Bills of Materials (BOM) and drawings necessary for manufacturing • Written API programming in FEMAP Nastran, automated Meshing and Analysis process. • Supported Production line, Managed ECR Engineering change Requests. • Established connections with vendors, Modified purchased parts based on change in application, availability and price. ### Design Engineer @ ATI Tracks, Inc Jan 2011 – Jan 2013 | Mount Vernon, Indiana • Analyze mechanical systems, including Finite Element (FEA) analysis for structural, fatigue, and vibration; enhanced current product by 30% of weight reduction without compromising load conditions. • Reduced costs by converting weldment designs into casting designs utilizing FEA; read and interpret blueprints, technical drawings, schematics, and computer-generated reports. • Installed Windchill PLM and configured based on organization and team, created Life Cycles and workflows. • Configured Vault management, migrated entire CAD data into Windchill PLM; trained employees to use Windchill 10.0 for CAD and non-CAD data management. • Produce and optimize mechanical components (shafts, frames, wheel, hubs...etc) for Modular Track systems; specify system components or direct modification of products to ensure conformance with engineering formation and performance specifications. • Extensive interface, including international travel, with end users, clients, customers and vendors to obtain and discuss project design requirements. • Scrutinized customer proposals, specifications, manuals, and other data to evaluate the feasibility, cost, and maintenance requirements of concepts and/or applications. • Confer with system engineers and other personnel to implement operating procedures, resolve system malfunctions, and provide technical information. ### Industrial Engineer @ Hoosier Wheel Jan 2008 – Jan 2010 • Achieved 5% reduction in scrap by implementing Lean Manufacturing TIM WOOD (Transportation, Inventory, Motion, Waiting, Over Production, Over Processing, Defects). • Increased production efficiency 11% by grouping job orders based on sequence of operations. • Calculated tolerance/confidence levels of parts using statistical process control methods. • Created manufacturing scheduling program in Visual C++; optimized schedules by implementing particle swarm optimization algorithm. • Trained new operators in basic measurements, OSHA safety, operating procedures, and quality standards; conducted production/quality audits. • Coordinated manufacturing, sales and quality control to meet time and customer requirements. ### Software Development Intern @ Nestlé Jan 2008 – Jan 2008 | Dekalb, Illinois • Participated in a project focused on optimizing process flow at Nestlé Distribution Center. • Estimated a savings of $3.1 million by implementing Putaway logic for warehouse management that balanced travel time and storage density. • Used Java to develop simulated algorithms to evaluate variations in travel time and storage constraints; attained 28% control on space utilization with a tradeoff of 13% on travel time. ### Teaching Assistant @ Northern Illinois University Jan 2007 – Jan 2007 • Teaching assistant for courses “Statistics for Engineering” and “Probability for Engineering”. • Graded student’s papers and helped them to understand the course. ### Production Engineer, @ MEKINS INDUSTRIES LIMITED Jan 2005 – Jan 2006 • Reduced overhead costs 8% by utilizing heuristic techniques to devise an inventory model for steel management. • Increased production by 10% through the creation and application of “bonus as a production rate” methodology. • Enhanced pallet layout by replacing plain sheet metal with corrugated metal; ensured margin of safety through FEA analysis with ANSYS engineering simulation software. • Proposed storage solution options based on customers technical requirements; forecasted required project inventory levels and obtained raw materials. • Reached daily production targets through production level planning and workload distribution. • Monitored production rates and inspected quality during production and before shipping. ### Sales Associate @ Hitachi Jan 2004 – Jan 2005 • Demonstrated Air Conditioning units for domestics and commercial use in Stores, Shows & Conventions. • Achieved 55% Regional sales • Sold 170% more units compared to previous year. ## Education ### Master of Business Administration - MBA in Business Administration and Management, General University of Illinois Urbana-Champaign Jan 2020 – Jan 2022 ### Master's degree in Industrial and systems engineering Northern Illinois University Jan 2006 – Jan 2008 ### Bachelor's degree in Mechanical Engineering Jawaharlal Nehru Technological University Jan 2001 – Jan 2005 ## Contact & Social - LinkedIn: https://www.linkedin.com/in/ayyawar --- Source: https://flows.cv/kapilayyawar JSON Resume: https://flows.cv/kapilayyawar/resume.json Last updated: 2026-04-07