Ram Charan Vuyyala

• Developed an inline CNC-compatible microscope system to capture cutting tool images for predictive maintenance. • Designed and prototyped custom mechanical enclosures and optical mounts in Siemens NX for CNC integration and mechanical durability. • Built an embedded system using Raspberry Pi and programmed in C++/OpenCV to stream images during live machining operations. • Developed a secure data streaming pipeline to transmit images to a server/cloud, enabling downstream ML-based toolwear analysis.

• Participated in an academic–industry collaboration project to support the testing and validation of a container-sized biogas plant. • Analyzed full system layout, studying interconnections between mechanical, electrical, and control subsystems. • Gained hands-on exposure to the Altenburg controller and its role in plant automation, including its scaled-down training model. • Developed working knowledge of PLC-based operation, signal routing, and system monitoring workflows for biogas plant commissioning.

Designed 700+ gearbox & coupling assemblies (fluid couplings, guards) in SolidWorks, Creo, Inventor, and AutoCAD per ASME/DIN/ISO/ANSI/AGMA. Delivered GD&T drawings, BOMs, and routings in SAP across 9 countries; managed PDM/Windchill. Led 5 sustainability projects & 1 NPD gearbox (DFM, compliance). Performed DFMEA, tolerance analysis, and spec reviews. Validated 14+ DriveWorks templates, trained juniors. Cross-functional collaboration achieved 98% on-time, 100% quality compliance.

• Converted legacy 2D/3D CAD drawings into parametric SolidWorks models, improving design reuse by 50% and enabling automation-ready geometry. • Migrated outdated product libraries into SolidWorks for integration into DriveWorks automation pipelines. • Assisted with VAVE (Value Analysis/Value Engineering) projects, contributing to early-stage cost-reduction proposals and design simplification initiatives.