THIRUMALAI R
Wiring Harness Design And Development
Tiruvannamalai,TN
Summary
Harness Design Engineer with 9+ years of experience, including 8+ years specializing in electrical harness design for automotive and electric vehicle projects. Skilled in HV harness routing, 3D electrical routing, schematic design, and vehicle-level issue diagnosis, with hands-on expertise in Capital Harness XC, Capital Logic, Capital Library, CATIA V5/V6, ENOVIA PLM, and PREEVision. Adept at process optimization, change management, and cross-functional collaboration, with a proven track record of innovation through patent filing and organizational awards. Seeking to leverage technical proficiency, problem-solving skills, and design robustness to contribute to innovative vehicle development, ensuring reliability, safety, and compliance in electrical systems
Overview
10
10
years of professional experience
1
1
Language
Work History
Senior Product Design Engineer
Mercedes-Benz Research and Development of India
12.2022 - Current
- Created schematics for telematics, sound systems, body controllers, and measurement components using the PREEVision tool.
- Defined wire sizes, colors, fuse ratings, and relay selections in compliance with industry standards.
- Identified fuse slots, conducted tri-party meetings, and maintained fuse documentation files.
- Performed sync checks, consistency error checks, and cleared issues for created schematics.
- Conducted project-level and system-level quality checks to ensure schematic accuracy.
- Evaluated and validated components for schematic creation to meet design and performance requirements.
- Handled change management for schematics, ensuring updates were tracked, reviewed, and implemented in compliance with standards.
- Honored with the Xtream Award in 2024 as part of a high-performing team recognized for best performance.
- Generated and executed new process optimization and automation ideas, improving efficiency.
- Ranked among the top eight finalists in KAIZAN at the organization-wide level.
- Received Process Innovation recognition in 2025 for pioneering improvements and driving efficiency gains.
- Filed a patent for a new clip-type invention, demonstrating innovation and technical expertise.
System Engineer
Tata Consultancy Service
05.2021 - 12.2022
- Executed 3D harness routing for LV and HV harnesses, ensuring optimal packaging and manufacturability using CATIA V5.
- Performed dynamic buckling checks and routing validation for moving parts to ensure durability.
- Conducted HV connector interface studies, and implemented Poke-Yoke coding creation for error-proofing.
- Carried out packaging studies for PDU, B-PTC, C-PTC, inverter, E-motor, and battery pack connector orientation.
- Completed HV charging socket routing studies in wheel arch locations for integration feasibility.
- Performed HV grounding impedance studies to validate electrical safety and performance.
- Analyzed ground stud size, pitch size, and production line assembly feasibility for manufacturability.
- Conducted interface clearance checks with interior trim, BIW, and seat structures.
- Studied service plug and safety loop locations based on crash feedback for enhanced safety compliance.
- Modified harnesses based on crash reports, and signed off on new interface requirements with counterparts.
- Recognized twice by management as a 'Gem' for exceptional performance and contributions.
Engineer
Tech Mahindra
11.2018 - 05.2021
- Deputed to Mahindra Research Valley for design and development projects.
- Designed, developed, and procured components for mule car preparation to support initial-level engine testing.
- Component development activities, including TSO and TKO validation for new parts.
- Designed and developed wiring harness channels and brackets for vehicle integration.
- Conducted interface clearance and alignment checks in collaboration with counterparts, like the vehicle integration and interface team.
- Created schematics and executed DRC checks using Capital Logic for design validation.
- Routed cross-car beam, engine, and engine compartment harnesses in 3D using CATIA V5.
- Prepared 2D layouts, added child parts, and generated BOMs using Capital XC.
- Performed overall vehicle-level testing and validation of E&E components, ensuring sign-off compliance.
- Conducted fuse blow, charge balancing, and voltage drop tests at the vehicle level.
- Executed durability and performance trials, including Figure-of-8, water wading, hill hold, road condition, winter trials, pressure-temperature, and cold chamber testing; analyzed reports for product improvement.
- Identified and rectified issues using DTC reports to enhance reliability.
- Conducted slam tests for door grommets and handles, and rattle noise tests for vehicle harnesses.
- Supported new feature integration trials (e.g., panoramic sunroof, flush handles), and generated validation reports.
- Performed harness protection studies based on zonal thermal analysis reports.
- Conducted ground impedance and voltage drop studies for all electrical systems.
- Verified the gap and flushness of E&E components with trim parts for fit and finish.
- Created wiring harness schematics, executed 3D routing, and released drawings in ENOVIA PLM.
- Performed a strip-down analysis of failed wiring harnesses, and coordinated with suppliers for corrective reports.
- Received six consecutive Spot Awards from various departments in recognition of outstanding performance and cross-functional contributions.
Junior Design Engineer
SRI KRISHNA POWER ENGINEERING & CONSULTANT
10.2017 - 10.2018
- Collaborated at the customer site – Ashok Leyland Tech Center – to deliver technical solutions.
- Designed capital symbols and developed libraries to streamline engineering workflows.
- Conducted switch toggling, fuse blow, and voltage drop tests using Capital Logic for system validation.
- Developed power distribution layouts and created fuse trees using MS Visio.
- Generated XCV files for schematic design and CAD integration to streamline engineering workflows.
- Performed functionality testing and simulations (SIMSTRESS, SIMPROVE, SIMTOOL) using CHS to validate system performance.
- Generated DRC reports, identified design problems, and implemented corrective actions to ensure compliance and quality.
- Developed 3D designs with interface checks, and ensured design robustness using CATIA V5 and V6.
- Prepared harness installation drawings for production assembly to ensure accuracy and manufacturability.
- Prepared harness layouts using Harness XC, and integrated additional components to support production requirements.
- Prepared cable flattening and detailing in compliance with manufacturing guidelines.
Graduate Apprentice Trainee
Sundaram Fasteners Pvt Ltd.
06.2016 - 06.2017
- New product development and manufacturing using CNC and VMC technologies.
- Machine operation programming, effective tool life management, and consistent part quality maintenance.
- Learned proper and safe use and maintenance of power tools, hand tools and safety equipment.
- Learned wide range of simple and complex techniques from on-the-job training.
- Worked under guidance of experienced professionals to learn trade best practices and techniques.
- Adhered to company policies, procedures, and safety guidelines during daily work activities.
Education
B.E - Mechanical Engineering
SKP Eng., College
Tiruvannamalai, India01-2016
HSC -
Sri VDS Jain Hr., Sec School
Tiruvannamalai, India01-2012
SSLC -
Municipal High School
Tiruvannamalai, India01-2010
Skills
Electrical system design
3D modeling expertise
Patent and IP awareness
Technical solution development
Failure mode analysis
Design validation methods
Interests
Reading books, Site seeing and cooking
Declaration
I hereby declare that the particulars given above are true to the best of my knowledge.
Timeline
Senior Product Design Engineer
Mercedes-Benz Research and Development of India
12.2022 - Current
System Engineer
Tata Consultancy Service
05.2021 - 12.2022
Engineer
Tech Mahindra
11.2018 - 05.2021
Junior Design Engineer
SRI KRISHNA POWER ENGINEERING & CONSULTANT
10.2017 - 10.2018
Graduate Apprentice Trainee
Sundaram Fasteners Pvt Ltd.
06.2016 - 06.2017
B.E - Mechanical Engineering
SKP Eng., College
HSC -
Sri VDS Jain Hr., Sec School
SSLC -
Municipal High School