Engineer working at the intersection of lean production, data & traceability, and equipment commissioning : from battery-cell factories to embedded prototypes.
FOCUSLean · Traceability · Automation
CURRENTLYM.Sc. Thesis @ Fraunhofer FFB
STATUSOpen to opportunities
SCROLL - THE VALUE STREAM
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By the Numbers
0%
Human Errors Reduced
// Poka-Yoke & Kaizen @ Lear
0K
Seat/yr Line Validated
// EOL commissioning
0
Electrode Stations Traced
// Mixing → Slitting
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M.Sc. GPA
// German scale (1.0 best)
01
The Value Stream
STATION 01 - Foundation2017 - 2021
B.E. Mechanical Engineering
Savitribai Phule Pune University · Pune, India
Built the engineering foundation - CAD (CATIA V5, SolidWorks), lean tools, and operations management: alongside hands-on Arduino prototyping in smart parking and solar tracking.
CATIA V5SolidWorksArduinoLean Basics
STATION 02 - Industry10/2021 - 09/2023
Industrial Engineer
Lear Corporation · Pune, India
Commissioned and validated automated End-of-Line test systems for a 100K-seat/year assembly line, owning the full lifecycle from RFQ and FAT/SAT through root-cause resolution and production handover. Led Poka-Yoke and Kaizen initiatives that cut human errors by 60%.
FAT/SATPoka-YokeVSMPFMEA8D / 5-Why
STATION 03 - Mastery10/2023 - 07/2026
M.Sc. Advanced Manufacturing
TU Chemnitz · Chemnitz, Germany · GPA 1.82
Deepened the digital toolkit: digital twins and Industry 4.0, digital ergonomics (ema, MTM, EAWS), additive manufacturing, and life-cycle engineering: bridging shop-floor practice with data-driven methods.
Digital TwinIndustry 4.0Digital ErgonomicsAdditive Mfg.
STATION 04 - Frontier2026 · Current
Master's Thesis - Traceability in Battery Cell Production
Fraunhofer FFB · Münster, Germany
Designing a spatially resolved traceability architecture for electrode manufacturing: capturing process and quality parameters across every station and web speed, linking OPC UA machine signals to traceable production events.
TraceabilityOPC UABattery CellData Engineering
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PROJECTS
Featured · Master's Thesis
Spatially Resolved Traceability in Battery Cell Electrode Production
FRAUNHOFER FFB · MÜNSTER · 2026
A traceability architecture that captures 100% of process and quality parameters across all electrode manufacturing stations: Mixing, Coating, Drying, Calendering, and Slitting. Mapped OPC UA equipment signals to traceable production events and designed timestamp-validation logic that surfaced architectural failures, working with FFB Prefab machines to make data acquisition feasible for Fab-scale lines.
A surface-quality sensor scans the moving electrode web and streams every reading to the server over OPC UA — building spatially-resolved traceability. Scroll to run the line.
Problem
Fab-scale electrode lines run roll-to-roll at 5–150 m/min across five coupled stations. Without spatial linkage, a defect found later at the cell level cannot be traced back to the exact web position and process parameters that caused it.
Approach
Mapped OPC UA equipment signals to traceable production events, designed timestamp-validation logic, and worked with FFB Prefab machines to make data acquisition feasible at Fab scale.
Result
A traceability architecture targeting 100% parameter coverage from Mixing to Slitting; the timestamp-validation logic surfaced architectural failure modes early in the design.
An interactive Power BI dashboard built to monitor performance KPIs: sales, profit, and quantity broken down by region, state, and year. with drill-downs, a geospatial map, and year-over-year comparison tables for fast, strategic decision-making.
Power BIDAXData VisualizationKPI Modelling
Problem
Sales and production KPIs were scattered across sources, slowing strategic, region-level decisions.
Approach
Built an interactive Power BI model with DAX measures, drill-downs, a geospatial map, and year-over-year comparison tables.
Result
A single view of sales, profit, and quantity by region, state, and year — enabling fast, strategic decision-making.
A wearable ergonomic system that detects unsafe lifting in real time. Six micro:bit accelerometer modules sewn into a jacket and trousers stream acceleration data over radio; a Python application filters and interpolates the signals, computes four body angles (back, back-arch, knee, arm), and classifies posture into risk zones - driving live GUI feedback and a buzzer warning on high-risk movements.
Sensors
6 × micro:bit
Body Angles
4 tracked
Risk Scenarios
81 classified
Feedback
Real-time GUI + buzzer
// The prototype - six sensor modules on jacket & trousers
// Real-time GUI: raw sensor data, calculated angles, risk state & trend charts// Posture classification: high-risk to low-risk lifting sequence
Body-worn micro:bit sensors track back, knee and arm angles in real time. As the lift gets riskier the EAWS zone climbs from green to red and the buzzer fires. Scroll to lift.
Problem
Manual-handling injuries come from unsafe lifting, yet workers get no real-time feedback on risky posture.
Approach
Sewed 6 micro:bit accelerometers into a jacket and trousers streaming over radio; a Python app filters and interpolates signals, computes 4 body angles, and classifies 81 risk scenarios.
Result
A real-time GUI plus buzzer warns the wearer the moment a high-risk lifting movement is detected.
Featured · Equipment & Automation
Backup End-of-Line Tester
LEAR CORPORATION · SIEMENS S7-1200 · 2022–2023
A backup end-of-line tester that keeps a high-volume seat line running when the main EOL system goes down. Built around a Siemens S7-1200 PLC, it verifies the two safety-critical seat parameters: seat-belt continuity and the occupancy-detection sensor (ODS): so production can keep tracing and validating seats at minimal cost and near-zero downtime.
Critical Checks
Seat Belt · ODS
Controller
Siemens S7-1200
Role
Backup to main EOL
Priority
Min. cost & downtime
// Control core, CPU 1212C with SM 1223 digital I/O and SM 1231 analog input modules
// Test connector - interfaces with the seat harness for the safety checks
The ODS tester descends and the harness connector engages, verifying the two safety-critical parameters before the seat passes. Scroll to test.
Problem
When the main End-of-Line system goes down, a high-volume seat line can no longer trace or validate seats — forcing costly stoppages.
Approach
Built a backup tester around a Siemens S7-1200 PLC that verifies the two safety-critical parameters: seat-belt continuity and the occupancy-detection sensor (ODS).
Result
The line keeps tracing and validating seats at minimal cost and near-zero downtime.
Featured · Lean & Error-Proofing
Spatial-Arm Torque Poka-Yoke
LEAR CORPORATION · ATLAS COPCO · MES-INTEGRATED
An error-proofing system that makes a missed or loose bolt impossible at a critical station. An Atlas Copco torque tool on a position-sensing spatial arm only enables when it reaches the designated bolt; each rundown is verified against torque and angle limits and logged to the MES as permanent per-fastener history. Operators can't skip a bolt, and every "Good" result is traceable - driving defects at the station toward zero.
Mechanism
Position-enabled tool
Verification
Torque + angle limits
Traceability
Per-bolt → MES history
Target
Zero missed/loose bolts
// Torque tool on the position-sensing spatial arm// Station screen: rundown of 22.4 Nm / 12° verified against limits and traced to the MES
Raw material flows in, the line transforms it, and finished product flows out — minimal waste, maximum flow. Scroll to move the stream.
Problem
Operators could miss or under-torque a bolt at a critical station, with no per-fastener traceability of what actually happened.
Approach
Mounted an Atlas Copco tool on a position-sensing spatial arm that enables only at the designated bolt; each rundown is verified against torque and angle limits and logged to the MES.
Result
Operators cannot skip a bolt, and every “Good” result is permanently traceable — driving station defects toward zero.
Research · thyssenkrupp
Recycled High-Performance Polymers
Study on integrating recyclate into PEEK, PTFE, and PAI: assessing market availability, pricing, and mechanical/thermal performance versus virgin material, and proposing strategies for sustainable use aligned with circular-economy goals.
