ERICK MAINA GITHINJI

• Performed rigorous stress analysis of electric vehicle drive train mechanical structures, motorcycle frame structures, and electric motor mounts, ensuring all components met safety and performance requirements.
• Led the design and development of critical components for Roam's electric motorbike and electric vehicles, ensuring structural integrity, optimal performance, and adherence to internal and customer requirements.
• Streamlined hardware designs by using hand calculations, finite element analysis(FEA), Computer-aided Engineering (CAE), Geometric Dimensioning and Tolerancing (GD&T), and Computer-aided designs (CAD) to optimize hardware designs to ensure adherence to internal and customer requirements.
• Led proactive Design for Manufacturability (DFM) strategies by actively engaging in the early and continuous stages of product development. This approach facilitated seamless collaboration between design and manufacturing teams, ensuring that new products were mechanically feasible for production through multiple international trips.
• Led the design and implementation of high-efficiency welding jigs and fixtures for Roam Electric vehicles, optimizing production line throughput and reducing quality defects.
• Enhanced cross-functional collaboration by designing, implementing, and optimizing manufacturing processes and facilities for automotive manufacturing that impacted cost, and timing, to improve overall product delivery.
• Owned the entire hardware delivery timeline, from inception to launch and subsequent re-use, ensuring milestones were met on schedule.
  Leading cross-functional teams to successfully support Roam's contract manufacturing suppliers and car programs locally and globally
• I managed complex projects, coordinating with diverse stakeholders, and resolving technical challenges. My role has also involved extensive international travel, providing me with a deep understanding of global manufacturing practices and cultural differences
• Process Engineering - Designed and developed technically complex processes to improve quality and efficiency. Utilized statistical tools (such as GR&R, SPC, and Cp/Cpk) to ensure processes and fixtures are scalable and are continuing to perform properly once qualified
• Product Engineering – Worked in all phases of a product from concept to repeat manufacturing to end-of-life. Provided production support engineering concerning technically complex testing methods, procedures, and analysis.
• Coordinated comprehensive cross-functional assessments integrating requirements, design, qualification, and capabilities
• Managed the development of detailed Request for Quotation/Proposal (RFQ/RFPs) outlining automated equipment design specifics, delivery schedules, essential documentation, and qualification criteria for vendor and contract manufacturer evaluation
  This ensured precise alignment between project expectations and supplier deliverables, resulting in optimized efficiency and cost-effectiveness for the company
• Failure Data Analysis - Planned, developed, and implemented technically sophisticated procedures for the testing and evaluation of soon-to-be-released products. Specified tests to be performed, compiled data, and made recommendations for product design changes and final assembly standards. This included the use of (DOE) and statistical analysis using Six Sigma principles.
• Implemented proactive Design for Manufacturability DFM strategies by actively engaging in the early and continuous stages of product development. This approach facilitated seamless collaboration between design and manufacturing teams, ensuring that new products were mechanically feasible for production
• By integrating manufacturing perspectives from the outset, it significantly minimized potential production bottlenecks, reduced manufacturing costs, and accelerated time-to-market, thereby enhancing the company's competitive edge in delivering high-quality, cost-effective products
• Designed and developed innovative BIW tooling solutions for electric vehicles, considering the unique requirements of these vehicles, such as weight reduction, battery integration, and crashworthiness. This included designing welding fixtures, stamping dies, and other tooling used to manufacture EV BIWs
  My work helped to improve the efficiency and quality of EV production, while also reducing costs. Increased production efficiency by designing and implementing process improvement strategies in mechanical operations.

Brought in to contribute to the design and development of various electric vehicles

• Successfully deployed the internal design process by implementing DFMEA, DFA and DVP processes to over 1000 parts/components to support end-to-end product development process to optimize manufacturability and reduce cost at every stage including virtual validation, CAE analysis, HW/SW integration, and production ramp-up.
• Acted as the technical interface between Roam and external suppliers and contract manufacturers throughout the hardware lifecycle. From concept inception to assembly, launch and component reuse, I consistently ensured on-time delivery and project success. This involved extensive international travel, providing me with a deep understanding of global manufacturing practices and cultural differences.
• Enhanced hardware development by utilizing GD&T to drive vehicle quality goals and tooling design. This ensured optimized tooling design, ensuring dimensional accuracy and consistent production of high-quality vehicles.
• By implementing DFMEA, DFA, Geometric Dimensioning and Tolerancing (GD&T) and designing effective fastening solutions, I reduced design iterations and improved design accuracy, positively impacting manufacturing design databases
• Integrated and packaged a wide variety of electrical components in CAD (Catia, Onshape, Solidworks) to create compact, lightweight, and reliable electrical systems for electric vehicle. This included batteries, motors, inverters, converters, and other components
• I also worked closely with engineers and manufacturing teams to ensure that the designs were manufacturable and cost-effective
• Acted as a central point of contact, facilitating seamless team communication and coordination
• Leveraged a deep understanding of requirements to drive functional and aesthetically appealing design. Resulted in exceptional solutions that met technical and market demands.
• Skilled at working independently and collaboratively in a team environment.

• Gearbox is an initiative that aims at improving the ecosystem for hardware entrepreneurship by providing flexible working space, shared prototyping facilities, training in manufacturing, fabrication and design as well as mentorship, availing of investment opportunities, incubation and acceleration, and community development
• Brought in as a contract design engineer, providing mechanical engineering services to various clients
• Supported the development of manufacturing drawings and provided assistance to production teams, resulting in improved efficiency and product quality
• Implemented an innovative tool maintenance process for prototyping shop equipment, delivering enhanced efficiency and reducing downtime.

• Installed, serviced, and maintained HVAC equipment in over 50 facilities across Kenya, ensuring optimal performance and indoor comfort.
• Diagnosed and resolved HVAC issues to minimize downtime and maximize customer satisfaction in Kenya, Uganda, Tanzania, and Rwanda.