Umesh Saini

Background

About Umesh Saini

Mechanical Product Design professional with over 8 years of experience delivering engineering solutions across automotive and hydrogen fuel system domains. Proven expertise in leading multidisciplinary projects involving product design, structural analysis (FEA), validation testing, field failure RCA, VAVE, and continuous improvement automation. Led FEA-driven design and validation of Powertrain (Transmission, Valvetrain) and Hydrogen Fuel System components—from concept to market launch—for top global OEMs. Mechanical Engineer | FEA & Product Design Specialist | DFSS Green Belt My core strengths include: Solving complex engineering problems using DFEM/GFEM modeling, fatigue analysis, and nonlinear simulations with tools like ANSYS and Nastran. Applying Design for Six Sigma and DFMEA principles to create structurally robust, certifiable products. Creating CAD models and GD & T-compliant drawings using Creo/SolidWorks; managing data via PLM systems like Enovia. Utilizing tolerance stack-up and CETOL 6σ for manufacturability and functional precision. Driving simulation-led design optimization (topology, DOE, parametric studies) to meet performance and cost targets. Automating repetitive analysis workflows using Python/VBA, improving consistency and turnaround time. Familiarity with technical standards and quality frameworks like IATF 16949, ISO 9001, and CSA HGV 3.1. Extensive collaboration experience with global teams across NA, EMEA, and APAC. EXPERTISE: FEA, ANSYS, Nastran/Patran, HyperMesh, DFSS, CATIA, Creo, Sigmetrix CETOL 6σ, DFMEA, Ansys DesignXplorer, Tolerance Analysis, DOE, Python, Minitab,@Risk, Enovia. Product design through simulation is my passion. I thrive on solving real-world structural challenges and applying advanced analysis techniques to ensure safety, performance, and innovation. I’m always eager to learn, collaborate, and deliver excellence to stakeholders and customers.