Shiju Kallan Valappil

I am a highly motivated and detail-oriented Mechanical  Engineer with over 16 years of experience in the field. I hold an Engineering Diploma in Tool & Die from Kerala Govt. Polytechnic, equivalent to MBO Level 4 in the Netherlands. Additionally, I have completed a post-diploma program specializing in Mechanical Design through one year of regular classes.

Throughout my career, I have gained extensive experience in product development, re-engineering, and reverse engineering of medical devices, consumer products, and home appliances. A pivotal strength of mine lies in successfully leading cross-functional teams to achieve optimal results, improving product performance, and providing cost-effective design solutions. I have successfully managed the entire product development process, from idea generation to supporting the final product.

In my current position as a Mechanical Design Engineer at Philips Consumer Lifestyle, Netherlands, from January 2023 through L&T Technology Services on-site, I was responsible for leading a team in designing and developing an Epilator. This involved collaborating with cross-functional teams, conducting feasibility studies, and ensuring that the designs met both performance and budgetary requirements. The product is designed to comply with EU regulations for 2025, integrating Right to Repair (R2R) principles and aligning with Sustainability Initiatives, with a specific focus on reducing FCP and enhancing profitability.

I am proficient in designing plastic and sheet metal parts, castings, and machined components from concept to production release. I have experience with various 3D CAD modeling tools such as SolidWorks, Siemens NX, and ProE (Creo), including surface modeling. Additionally, I am knowledgeable in FEA, materials selection, different manufacturing processes, and ISO and ASME standards.

As a Highly Skilled Migrant (HSM) visa holder with a Dutch driving license, I am open to relocating within the Netherlands based on the job location. Additionally, I am actively participating in a Dutch course called 'Nederlands in Gang' to obtain a Dutch language certificate.

PROFESSIONAL EXPERIENCE

Senior Mechanical Design Engineer and Development Lead | Philips Consumer Lifestyle BV, Drachten, Netherlands | January 2023 – Present | Contract Role through L&T Technology Services (India).

•Product Development Leadership: Spearheading the design and development of a corded epilator device, including shaving and trimming attachments, as well as a non-corded, rechargeable, watertight shaving device for Philips.

•Profitability Improvement: Leading a project with a primary focus on profitability enhancement through cost reduction initiatives.

•Regulatory Compliance: Ensuring compliance with the Right to Repair (RTR) directive as per EU regulation for 2025, facilitating home repair of products.

•Gap Analysis: Conducted in-depth gap analysis with existing products, identifying key areas for improvement.

•High-Level Concept Generation: Led brainstorming sessions and high-level concept generation, fostering innovation, and driving product development.

•Collaborative Design: Coordinated closely with cross-functional teams, particularly Electrical Engineers, to optimize PCBA layout design, and worked with the FEA team to ensure the structural robustness of mechanical components.

•Prototype Development: Oversaw the entire prototype build process, from design verification to testing phases.

•BOM Management: I managed the creation of preliminary Bills of Materials (BOMs) and BOM cost calculations based on quotations from various suppliers. Additionally, I created the Product E-BOMs for different SKUs based on the SKU matrix in the Windchill PLM System.

•Detailed CAD Design: Executing detailed CAD design with a focus on Design for Manufacturability (DFM) and Design for Assembly (DFA) principles.

•Engineering Drawings: Demonstrate expertise in creating detailed engineering drawings and specifications, contributing to accurate design documentation.

•Tooling and Industrialization Support: Collaborating on tool build and supporting industrialization engineers in validating manufacturing processes.

•Tolerance Stack-up Analysis: Conduct tolerance stack-up analyses, updating drawings to ensure precision and reliability.

•Documentation and Compliance: Creating and maintaining project documents as per PDLM Master Lists and ensuring compliance with design and regulatory standards.

•Sustainability Initiatives: Contributing to sustainability goals through plastic-free packaging and the use of recycled materials.

•Project Management: Updating and adhering to project management plans to meet project objectives and timelines.

•CAD and PLM Tools: Proficiently using Unigraphics NX, Windchill PLM, and PDM systems for design and project management.

•Concept to Verification: Overseeing the entire product development cycle, from concept generation to verification and testing, ensuring the product meets quality standards and profitability goals.

•Troubleshooting and Creative Problem-Solving: Swiftly diagnose and resolve mechanical issues, minimizing disruptions to project timelines.

SKILLS PORTFOLIO

New Product Design and Development
Design for Manufacturability /Assembly 
Cross-Functional Team Leadership
Project Planning and Scheduling 
Cost-Effective Design.
Material Selection and Management 
Manufacturing Process Optimization
CAD Software Proficiency
Geometric Dimensions and Tolerances (GD&T)
Finite Element Analysis (FEA)
Product Lifecycle Management (PLM) & Product Data Management (PDM)
Prototyping and Testing & Design Verifications.
Problem-Solving and Continuous Learning
Regulatory Compliance
Process Validation in Regulated Manufacturing

  TECHNICAL SKILLS

Unigraphics NX, SolidWorks, Autodesk Inventor ,Pro-Engineer (PTC Creo), AutoCAD
Windchill PLM & PDM
Product Configuration & BoM Management
Microsoft Excel, Word, Presentation Software

•Post Diploma in Tool Design/Product Design | Jan 2004 to Jan 2005 | Board of Nettur Technical Training Foundation (NTTF).

•Engineering Diploma in Tool & Die (Equivalent to MBO Level 4) | April 1998 to April 2001 | Kerala Govt. Poly Technic/ Kozhikode

•Technical High School Leaving Certificate (Secondary Schooling.) March 1998, State Board of technical education, Kerala Govt.