Harshalkumar Fadadu

Master's thesis: Analytical Shim Calculator for BIW Assembly – Predicting Ranges for AutoForm Build Optimizer. End-to-end forming & assembly simulation in AutoForm (springback deviations); calculation logic for optimal shim ranges to reduce physical tryout loops; virtual shimming scenarios with AutoForm Build Optimizer; influence of residual stresses on shimming accuracy; Zeiss Inspect (GOM) correlation with 3D mesh data to resolve gap & flush deviations.

Reviewed body panel designs in CATIA and AutoForm against production requirements. AutoForm simulations to evaluate manufacturability, predict deformations and identify stress/bending issues in forming. Worked with design engineers to resolve manufacturing and load-distribution issues and gave actionable design feedback. Liaised with press shop and production on setup changes (clamps, fixtures) to improve quality. Supported continuous improvement in design, quality and production efficiency.

Ensured strict adherence to product quality standards through rigorous inspections. Improved manufacturing efficiency and optimised production workflows. Conducted Non-Destructive Testing (NDT) to assess material integrity.

Supervised and verified production output to ensure compliance with quality standards. Compiled performance and progress reports for supervisory management. Maintained production parameters within defined tolerance limits.

Ensured precise dimensional accuracy for seamless assembly in the production process. Improved durability and performance through proper finishing techniques. Conducted rigorous inspections to maintain high-quality manufacturing standards.

Analyzed metal properties to optimize casting processes and material performance. Conducted rigorous quality checks to ensure defect-free castings.

Specialisation: Foundry Technology. Master's thesis at AUDI AG on virtual shimming optimisation for BIW assembly (AutoForm Build Optimizer).

Grade: 9.16 / 10

Grade: 9.36 / 10 – First Class with Distinction.