Vivek Nair

Core Responsibilities.

• Take ownership of the complete design, development, and validation of the vehicle's electrical distribution system. This includes both low voltage (LV) and high voltage (HV) wiring harnesses, power distribution boxes, and connectors.
• As a key HV expert, below are the roles:
• Design and develop the HV electrical architecture for EVs, ensuring proper insulation, shielding, and safety features.
• Integrate HV systems with the Battery Management System (BMS), electric motors, power electronics (inverters, DC-DC converters), and charging systems.
• Conduct HV cable sizing and routing, taking into account current carrying capacity, thermal management, and safety regulations.
• Collaborate with safety and quality teams to perform HV system FMEA (Failure Mode and Effects Analysis), and ensure compliance with functional safety standards like ISO 26262.
• Design and develop wiring harnesses for all LV systems, including infotainment, lighting, body electronics, and ADAS (Advanced Driver-Assistance Systems).
• Manage the design of fuse and relay boxes, grounding strategies, and component selection for optimal performance and cost.
• Ensure robust communication within the LV network, working with protocols such as CAN, LIN, and Ethernet.
• Serve as the technical lead and primary point of contact for EDS, working closely with below teams.
• Mechanical Engineering to ensure proper routing and packaging of harnesses within the vehicle.
• Power Electronics and Controls teams for seamless integration of hardware and software.
• Manufacturing and production to provide build support, troubleshoot issues on the assembly line, and implement design-for-manufacturability (DFM) principles.
• Technical Documentation & Standards:
• Create and maintain detailed technical documentation, including schematics, 2D/3D harness drawings, and component specifications.
• Ensure all designs and processes adhere to relevant automotive industry standards and regulatory requirements.
• Mentor and guide junior and mid-level engineers, sharing your deep knowledge in both LV and HV systems.
• Lead design reviews and provide technical guidance to resolve complex engineering challenges.
• Work with and manage external suppliers for electrical components (wires, terminals, connectors, ECUs), ensuring quality, reliability, and on-time delivery.
• Evaluate new technologies and components from suppliers to continuously improve vehicle electrical systems.

Based on the project charter, creating concept sheets with an impact on design, labor, and part cost estimates.

Attending vehicle architecture meetings and coordinating with a cross-functional team for the packaging of subsystems on the vehicle. With the team's agreement, freezing 3D layouts in the master model layouts.

Creating schematics based on feature codes and system requirements in capital logic.

Distributing circuits based on the packaging of modules and parts, while simultaneously finalizing interconnect cavities with various cross-functional teams.

Performing DFMEA for design changes and proving DVP for testing the changes.

Releasing deliverables like circuit diagrams, wiring harness diagrams, part drawings, and getting new parts added to the library using various capital tools.

Responsible for detailed design and engineering bill of materials.

Attending builds for different stages of the product development cycle, collecting feedback, and implementing changes.

Overview of performance domains and the systems, factors that affect them. VA/VE, cost reduction idea evaluation, and implementation.

Leading a team of 12 members to manage multiple programs.

Coordination with the onsite team for project details.

Working on deliverables to the customer.

Executing projects with quality by conducting peer reviews and various analyses.

Attending daily project status meetings and getting feedback from the team.

Vehicle integration in terms of schematic diagrams and electrical parameters.

To lead and support a team of six members in drawing schematics as well as electronic wiring diagrams of the automotive electrical distribution system for Nissan Motors, Japan.

Project execution and planning with respect to resources and workload.

To draw and quality check the electronics wiring diagram and schematic diagram of the entire vehicle using Cabling Designer, ACE tool, Macro, MS Excel, and G2B Designer Server of Nissan Motors, Japan.

To prepare KPI, LLR, QRQC, error and cause analysis, etc., and to do quality documentation for electronics wiring diagrams for service manuals globally for Nissan Motors, Japan.

To interact with the design team of Nissan Motors, Japan, for improvement in the automotive electrical distribution system.

Good knowledge of automotive electrical distribution systems and automotive electrical machines, like alternators, starter motors, fuel injectors, C.D.I.s, various automotive sensors, ECUs, TCMs, BCMs, and combination meters (clusters).

Designing various wiring harnesses as per customer requirements.

Preparation of wiring harness drawings in CAD, joint charts, APL, etc.

Preparation of the terminal diagram transfer sheet for the conversion of the electrical circuit diagram into wiring harness drawings.

Day-to-day interaction with customers to understand and fulfill their requirements comprehensively.

Closing of the "Field Trial Report" for samples submitted and feedback observations during the trial.

To get the products approved by the customer and relevant agencies.

Modification, change, and implementation tracking prior to ECN as per customer requirement.

Continuously finding out the area for improvement, considering the quality, in the existing wiring harness.

To work out various analytical tools like PPAP, SCAP, PFMEA, etc.

Designing using electrical components, viz. Microcontroller, regulator, capacitors, resistor, etc. And interpretation of their data sheets, as per application requirements.

Design, development, test, and validation of analog circuits, signal conditioning schemes/digital circuit design/mixed signal circuit design.

Simulating various circuits using PSpice simulation software.

Analyzing the circuit's electrical and graphical parameters using PSpice.

Designing using various asynchronous communication protocols, such as LIN, K-Line, and CAN.

Testing the circuit by practically simulating the condition using various input/output devices, like a signal generator, oscilloscope, multimeter, spectrum analyzer, etc.

Drawing a wiring diagram for various panels of calibration equipment.

Drawing a circuit diagram in Pads Logic.

Coordinating the software development for the monitoring device.