About me

I'm a Mechanical Engineer based in the Bay Area.

Transforming ideas into functional machines and turning sketches into faster, cooler realities.

Aviva Jesse Levi

A passionate mechanical engineer and problem solver with a creative streak. I am always looking for opportunities to make a positive impact using my skill set.

Contact

+1 (857) 891 5410

alevi@mit.edu

San Jose CA

www.linkedin.com/in/aviva-levi/

Education

Massachusetts Institute of Technology, Cambridge, MA, Aug 22

Master of Engineering in Advanced Manufacturing and Design; CGPA: 5/5

Relevant coursework: Control of Manufacturing Processes, Elements of Mechanical Design, Medical Device Design
Thesis topic: Design and Manufacturing of the Extrusion Assembly for an Advanced Process Control Educational Device

Manipal Institute of Technology, Manipal, India, Jul 18

Bachelor of Technology, Mechanical Engineering; CGPA: 9.46/10; Gold Medallist

Relevant coursework: Metrology and Measurements, Design for Manufacturing and Assembly, Manufacturing Technology, Operations Research, Design of Mechanical Systems, CAD-CAM, Production, Planning and Control, Finite Element Methods (FEA)

Skills & Certifications

Certifications

Experience Design Thinking Certification (2020) – Bosch | Geometric Dimensioning and Tolerances (2020) – Indian Machine Tool
Manufacturers’ Association | Project Management Fundamentals (2020) –Bosch | Hello Design Thinking (2019) – IDEO U | Arduino Hands-On Workshop (2019) – Opencube Labs | Measurement System Analysis (2018) - Bosch

Skills

Work Experience

Lunar Energy, Mountain View, CA (Dec 23 - present)

Manufacturing Engineer

Responsible for New Product Introduction Manufacturing Lines and setting up sustainable process flows for high volume production:
- Setting up and optimizing processes and process flows in-house and at contract manufacturer locations by working with a cross functional team (Mechanical Design, Electronics Engineering, Firmware Engineering, Supply Chain, Logistics)
- Performing Gauge Repeatability and Reproducibility studies on tester and production equipment
- Designing fixtures for assembly processes and giving design for manufacturing and assembly (DfMA) feedback to the Design team

Tesla, Palo Alto, CA (Oct 22 - Dec 23)

Mechanical Design Engineer, Battery Structures

Responsible for the complete product lifecycle of 15 part numbers on the enclosure of the battery pack right from requirements definition, design concept, supplier management, testing, reliability to prototyping and high volume production:
- Optimize designs via analytical, numerical, and/or empirical assessments by collaborating closely with a cross functional team comprising Simulations, Reliability, Testing, Supply Chain, Vendors, Manufacturing, New Product Introduction, Quality, Metrology
- Prepare the 3D models and 2D prints (with GD&T definition) of each part and assembly
- Define test plans and pass-fail criteria for functional tests, design and manufacture fixtures for reliability testing of the parts and perform failure analysis of various parts that fail any tests
- Define reworks and the Production Control Plans for all the parts and also design go, no go gauges for quality control
- Work closely with Manufacturing, Equipment and Controls Engineering to solve issues faced on the production line
- Collaborate with suppliers for DFM feedback and tool development (large metal stampings and extrusions of Aluminum and Steel, foam gaskets – silicone and polyurethane, plastic - metal injection over molding)
- Lead engineering changes for design, reliability or manufacturing improvements throughout the lifecycle of the product

Bosch Limited, Bangalore, India (Jan 20 - Jul 21)

Assistant Manager – Sensors Product Development

Managed 16 O2 sensor projects (Gasoline, CNG and Diesel vehicle systems) of major Indian and Chinese automobile OEMs:
- Independently owned the complete project life cycle process for each vehicle to ensure on-time delivery of sensors to OEMs despite COVID disruptions by collaborating with global cross functional teams including vendors
- Conducted Design FMEAs, reliability studies, risk assessments and root cause analysis of failures for each project
- Drove 3 engineering change orders (ECOs) for quality improvement in series products which resulted in cost savings of $1.3M
Collaborated with simulation engineers and OEMs to derive optimal mounting guidelines for O2 sensors to reduce vibration loads:
- Designed, executed and analyzed experiments considering 3 mounting parameters of the sensor on the vehicle by using Design of Experiments (DOE) methodology which led to a 40% reduction in vibrations and led to gain in business of $80Mil from Indian OEMs

Technical Management Trainee (TMT) - (Jun 18 - Dec 19)

Spearheaded projects in various teams as a part of the TMT rotational program to understand product development from ideation to commercialization:
- Process Improvement Team – Fuel Injector Plant, Jaipur
  - Developed and validated 4 fuel injector blockage detection methods to be retrofitted onto a legacy function test bench at the end of the fuel injector assembly line; identified a new decision parameter using statistical data analysis in Minitab to achieve a 98% reduction in the manufacturing failures of the fuel injectors (Lean Six Sigma)
  - Led continuous improvement projects (CIP) to reduce non-value-added tasks through low-cost automation (Karakuri Kaizen)
- 2-wheeler ICE Systems Team
  - Led a system level cost reduction project (reduction of 25%) of integrating a novel fuel injection system onto a 2-wheeler ICE vehicle

Powertrain Solutions Intern (Dec 17 - May 18)

Conceptualized, prototyped, and iterated on the design of a new sub-component for a diesel fuel pump using Design for Manufacturability (DFM) principles which reduced the per piece cost by 2.5%

Projects

Design and Manufacturing of a 2-part Dispensed Seal (Aug 23 - Oct 23)

Tesla

This seal failed reliability tests and had production issues potentially delaying the start of production of the battery pack.
Led a cross-functional team across multiple time zones to ensure that these issues were resolved in time for start of production.

Design and Manufacturing of the Extrusion Assembly for an Advanced Process Control Educational Device (Jan 22 - Aug 22)

MIT; Featured in MIT News

Adopted the V-model methodology to define the functional requirements, make multiple prototypes and perform functional testing for the extrusion assembly for an advanced process control educational device.
Conducted a pilot manufacturing run of 10 parts which led to a DFM feedback loop.
Defined the final production level design and process plan to carry out another run of 15 parts.

I’ve called six cities across two continents home — collecting new foods, friends, and a few foreign phrases along the way. My passport might be a little crowded, but my sense of adventure has room for more!