Kissan Kapadia

• Designed and commissioned a Python automated electromechanical test bench for HV contactor operation, characterization, and endurance testing. • Integrated mechanical fixtures, actuation systems, sensors, DAQ, and electrical subsystems for repeatable long duration testing. • Executed ~1,000,000 cycle EOL endurance testing to evaluate reliability, wear, contact resistance, and performance degradation. • Analyzed transient inrush current behavior and contact resistance evolution to identify electrical stres

• Planned and executed CMB hardware validation campaigns including electrical preconditioning, accelerated thermal ageing, and EOL surge testing. • Reproduced HV transient and surge conditions on Cell Monitoring Boards using an Overstress Tester. • Applied Arrhenius based thermal ageing to assess long term CMB reliability and degradation behaviour. • Measured transient voltage and current behaviour using PicoScope, HV differential probes, and Hall effect current sensors. • Compared aged and unaged boards to

• Built ECU and HV battery electronics test benches for functional, electrical, thermal, mechanical, and ageing validation. • Integrated DAQ systems, oscilloscopes, current probes, thermal sensors, and electrical interfaces for repeatable testing. • Used Python based tools and PEAK System CAN interfaces for signal monitoring, diagnostics, automated data logging, and reporting. • Executed ECU and BMS related validation campaigns across operating loads and ambient conditions. • Diagnosed system level electric

• Led 20+ shop floor technicians and coordinated production planning across design, procurement, machining, fabrication, assembly, and quality teams. • Planned heavy machinery projects using WBS, Gantt charts, milestone tracking, and manufacturing progress reviews. • Converted engineering drawings and BOMs into executable manufacturing plans, routing decisions, and assembly workflows. • Coordinated suppliers, procurement, and internal teams to ensure material availability, production readiness, and on time

• Participated in a 4 week internship program focused on design and development of hybrid bike systems. • Gained exposure to mechanical design principles, automotive systems, hybrid powertrain concepts, and component integration. • Worked on basic CAD modeling, mechanical assemblies, and system level design understanding for hybrid vehicle applications. • Developed practical understanding of manufacturing, assembly workflows, and automotive engineering fundamentals.

• Led 7+ shop floor technicians in high volume production of self lubricating sintered bushes. • Owned tooling development from design to production release using SolidWorks and AutoCAD. • Improved yield and throughput through process optimization, VSM, waste analysis, and production feedback. • Resolved recurring tooling and dimensional issues using RCA, 5 Why, and pFMEA methods. • Optimized powder metallurgy tooling, material selection, and tolerances to improve dimensional consistency. • Applied SPC and

- Assisted in workstation set-up, tool selection, and subassembly verification using work orders and schematics. - Introduced lean/5S principles to optimize workflows, enhancing efficiency and organization. - Supported process documentation for improved part traceability and quality control at Hilti Manufacturing India.

- Assisted in the design, fabrication, and assembly of IBR steam boilers and heat exchangers. - Supported process documentation and facilitated coordination between manufacturing and engineering teams. - Participated in quality control checks, ensuring adherence to ISO 9001/14001/45001 and IBR/PESO standards.