About Me
I'm a Software Developer at TCS with hands-on experience developing enterprise Windchill PLM systems for global manufacturing clients. My work focuses on solving complex problems in document management, workflow automation, and system integration using Java, JSP, and Windchill APIs.
Experience Timeline: February 2025 - Present (10 months)
Specialization: Document Lifecycle Management, Workflow Automation, BOM Processing, API Integration
Major Projects
1. Document Management & Format Conversion System
Duration: March 2025 | Role: Java Developer
The Challenge: Manufacturing clients experienced data corruption when importing Excel documents into Windchill PLM. nbsp (non-breaking space) character encoding issues were causing document relationship failures, leading to 200% increase in client complaints.
Technologies: Java, Windchill API, Apache POI, JSP, MVC Architecture
Solution Approach:
- Built format validation layer to detect problematic characters before import
- Implemented character encoding normalization utilities
- Developed document relationship mapping system
- Integrated with existing Windchill import workflow
- Added comprehensive error logging and monitoring
Results & Impact:
✓ 80% reduction in document import failures
✓ 95% improvement in character encoding success rate
✓ 60% decrease in client support tickets
✓ 100% success rate for document relationship creation
2. Workflow Automation - ECR/ECN Processing
Duration: April - June 2025 | Role: Workflow Developer
The Challenge: Manual processing of Engineering Change Requests (ECR) and Engineering Change Notices (ECN) was causing 3-5 day delays. Engineers spent 4-6 hours manually identifying affected parts in complex Bill of Materials structures, missing 15-20% of downstream impacts.
Technologies: Java, Windchill Workflow Engine, BOM APIs, Change Management APIs
Solution Approach:
- Developed automated BOM traversal engine for complex product hierarchies
- Implemented workflow robot for ECR/ECN processing
- Built conditional routing logic based on change impact analysis
- Created automated reviewer assignment system
- Implemented real-time stakeholder notification system
Results & Impact:
✓ 65% reduction in processing time (5.2 days → 1.8 days)
✓ 90% reduction in manual effort (4-6 hours → 30 minutes)
✓ 18% improvement in affected object accuracy
✓ $50,000/month cost savings in engineering time
3. Object Initialization Rules (OIR) System
Duration: July - September 2025 | Role: PLM Developer
The Challenge: Manual part categorization and folder assignment was causing inconsistent data organization. Engineers spent 5-10 minutes per part on setup, with 25-30% classification error rate and frequent revision number conflicts.
Technologies: Java, Windchill OIR Framework, Lifecycle Management APIs
Solution Approach:
- Developed automated folder location assignment based on part attributes
- Implemented revision series management system
- Built lifecycle state automation logic
- Created configurable classification rule engine
- Integrated with existing Windchill part creation workflow
Results & Impact:
✓ 95% reduction in part setup time (5-10 min → 30 sec)
✓ 28% improvement in classification accuracy (70% → 98%)
✓ 92% reduction in folder location errors
✓ Consistent part organization across all product families
4. Advanced Query Optimization
Duration: August - October 2025 | Role: Performance Engineer
The Challenge: Performance issues with large dataset queries were causing timeouts and slow response times when processing manufacturing BOMs with 1000+ parts. QueryResult iterations were inefficient, causing memory issues and user frustration.
Technologies: Java, Windchill QueryResult APIs, SQL Optimization, Caching
Solution Approach:
- Analyzed and optimized QueryResult iteration patterns
- Implemented caching layer for frequently accessed data
- Developed batch processing for large datasets
- Optimized SQL queries and database indexing
- Implemented lazy loading strategies
Results & Impact:
✓ 70% improvement in query performance
✓ 85% reduction in memory usage
✓ Elimination of timeout errors
✓ Scalable solution for enterprise-scale datasets