SASTIKUMAR T G
Lead Engineer
Chennai,TamilNadu
Summary
Automotive EE Schematic and Wiring Harness Design Engineer with 9 years of expertise in wiring harness design, system architecture, AI automation, and RCA methodologies. Proven ability to optimize designs, reduce wiring complexity, and enhance manufacturing efficiency. Adept at leading cross-functional teams, implementing AI-driven process automation, and ensuring compliance with industry standards (ISO 6722, AIS-071)
Overview
9
9
years of professional experience
Work History
Lead Engineer
HCL Technologies
01.2023 - Current
- Client: Stellantis India (FCA Group), Chennai
- Tools used: CHS Modular/Logical 2021, Doc info, Devin, Ridbul, iSpeed
- Led the electrification of the Fiat Panda for Stellantis, successfully meeting key design milestones within project timelines.
- Achieved SOP launch for Fiat Grande Panda at timely for wiring harness commodity delivery and supporting secondary launches.
- Increased program efficiency by 10% by developing and implementing a diversity chart aligned with the product-grid.
- Delivered high-impact presentations on project milestones, risk factors, and red flags to stakeholders and global leadership, ensuring alignment with objectives.
- Translated functional architecture into detailed 2D wiring designs, applying option codes per STLA codification standards and product grid specifications.
- Optimized wiring harness design by integrating PDC, Ground, and CAN topology, reducing wiring complexity by 40% and boosting system efficiency by 25%.
- Facilitated cross-functional technical meetings with SEWS and Stellantis (STLA) stakeholders, resolving manufacturing issues and driving process improvements.
- Reviewed and forecasted design change implementations from the base program, ensuring seamless integration with minimal disruptions.
- Automated wire list generation using AI-powered macros, reducing processing time from 40 minutes to 5 minutes, significantly enhancing workflow efficiency.
- Mentored and trained work package teams, enhancing technical proficiency and fostering a collaborative work environment.
- Diagnosed and resolved build issues using root cause analysis (RCA) techniques, swiftly implementing corrective and preventive actions (ICA/PCA) for project continuity.
Design Engineer
IDC Engineering India Pvt. Ltd.
03.2019 - 01.2023
- Client: Mercedes Benz Research & Development India
- Tools used: Zuken E3 Cable, PREEvision, EPDM
- Led projects for Carline Series and AMG at Mercedes Benz Research & Development India (MBRDI), ensuring seamless wiring harness design and implementation.
- Provided expert-level LV schematic design support, resolving complex design challenges and enhancing system architecture compliance.
- Drawn and implemented schematic diagrams aligned with architectural requirements, integrating wire attributes per ISO 6722 standards.
- Developed a standardized process flow for schematic development, improving efficiency and training effectiveness from input to HDD output.
- Performed rigorous, error-free quality checks for E3 & PREEvision schematics, ensuring high-accuracy schematic validation.
- Optimized feature code complexity by 10%, improving software efficiency and reducing system redundancy.
- Managed multiple feature variants, functional codes, system codes, and modularization of IP codes, streamlining design integration.
- Acted as a Sourcing Single Point of Contact (SPOC), leading new resource training and ensuring compliance with client project requirements.
- Conducted SCAT analysis for component validation, automating processes and ensuring high-accuracy results across project milestones.
- Implemented AI-driven macros to automate quality checks, leading to a 5% improvement in quality assurance and error detection.
Graduate Engineering Trainee
SNF Components Pvt. Ltd.
05.2016 - 03.2019
- Tools used: AutoCAD, Creo Parametric, MathCAD Prime
- Led the development and launch of the Self-Loading Concrete Mixer (SLCM) as a New Product Development (NPD) at Bauma 2018, New Delhi, and securing CMVR approval through ARAI.
- Executed benchmarking analysis of SLCM electrical and hydraulic core functionalities, optimizing supplier selection and system performance.
- Designed and simulated electrical schematics using advanced software for conceptual circuit analysis, ensuring functional accuracy.
- Performed fuse sizing, wire selection, relay configuration, and component integration, aligning with application specific requirements.
- Engineered wiring harness designs from an OEM perspective, overseeing the end-to-end development lifecycle from conception to manufacturing.
- Developed a test bench for wiring harness validation, reducing assembly time by 25% and enhancing manufacturing efficiency.
- Drafted new nomenclature for the electrical and hydraulic device PN codification which reduces 20% of the time for aftersales team to identify the component.
- Performed Electrical tests for the electrical devices in the bench and developed test bench to perform the wiring harness correctness which reduces 15% of assembly time.
- Created a customized dashboard incorporating tell-tale attributes as per AIS-071 compliance, ensuring regulatory adherence.
- Drafted trouble shooting matrix which supports to the service engineer to identify the issue and fix in short span. Also, it improves to root cause analysis 30% more to identify relative devices.
Education
Bachelor of Engineering - Mechatronics
Kongu Engineering College
Higher Secondary Certificate - undefined
Sengunathar HSS
Secondary School Leaving Certificate - undefined
Sengunathar HSS
Skills
Automotive Wiring Harness
undefinedAccomplishments
- Filed Patent titled “Safety Interlock EV Charging system with single flap feedback” (Ref: 2024D103124)
- Consistently acknowledged with the "Team Excellence Award" for outstanding work on the Fiat Program - presented three times by Stellantis India.
- Awarded “Star Performer” of the year 2019 at SNF Components Pvt., Ltd for project management
Work Preference
Work Type
Full TimeLocation Preference
HybridRemoteOn-SiteImportant To Me
Flexible work hoursPersonal development programsWork-life balanceCareer advancementLanguages
Sourashtra
Bilingual or Proficient (C2)
Tamil
Bilingual or Proficient (C2)
English
Upper intermediate (B2)
Hindi
Beginner (A1)
German
Beginner (A1)
Timeline
Lead Engineer
HCL Technologies
01.2023 - Current
Design Engineer
IDC Engineering India Pvt. Ltd.
03.2019 - 01.2023
Graduate Engineering Trainee
SNF Components Pvt. Ltd.
05.2016 - 03.2019
Higher Secondary Certificate - undefined
Sengunathar HSS
Secondary School Leaving Certificate - undefined
Sengunathar HSS
Bachelor of Engineering - Mechatronics
Kongu Engineering College
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