SARAVANAN RAMASAMY

Lead Mechanical / Systems Engineer – Rail & Rolling Stock

• Led a team of 5 engineers delivering high‑quality products on time and within budget for DT6, RENFE, FGC, projects, while driving continuous improvement initiatives across the engineering function.
• Planned and managed engineering workloads, budgets, and schedules across project phases (S‑Phase, P‑Phase, C‑Phase), ensuring alignment with program milestones.
• Collaborated closely with multidisciplinary teams to integrate mechanical systems, defining interfaces with car body, interiors, electrical equipment, and mechanical fittings.
• Designed and optimized mechanical systems and components for high‑speed trains, metro, and tram platforms, improving reliability, performance, and compliance with international safety standards.
• Delivered cost‑effective and weight‑optimized design solutions, reducing lifecycle and maintenance costs through advanced CAD modelling, DFM/DFA/DFS principles, and validation activities.
• Served as Design & Development Engineer for side linings, end walls, door pillars, and electrical cubicles, ensuring compliance with styling, manufacturing, industrialization, interface, and FEA constraints.
• Led design activities from concept through industrialization, focusing on mounting strategies, hatch kinematics, Gaps & Flushness (G&F), PQ, fire & safety (F&S), and robustness.
• Conducted cross‑functional design reviews (CFT) and facilitated weekly REX / knowledge‑sharing sessions to raise team capability and technical excellence.
• Directed train cab and saloon system design, guiding programs through detailed design, validation, and industrialization phases.
• Developed and implemented vehicle system integration solutions to meet customer, regulatory, and operational requirements.
• Prepared vehicle layouts and concept architecture studies to support bid and pre‑development projects, translating requirements into feasible engineering solutions.
• Served as Design and Development Engineer for side linings, end walls, door pillars, and electrical cubicles, ensuring robust and compliant designs.
• Engineered products in alignment with styling, manufacturing feasibility, industrialization, interface requirements, and FEA constraints.
• Drove cost‑effective design solutions to meet budgetary and program targets without compromising quality or performance.
• Prepared detailed engineering plans and workload distribution for mechanical and electrical design activities, aligned with project phases (S‑Phase, P‑Phase, C‑Phase).
• Analyzed and managed mechanical and electrical interfaces across all requirement areas to ensure system compatibility and integration.
• Led design activities from concept through detailed planning and industrialization, focusing on optimized mounting strategies, weight management, DFM/DFA/DFS, fire & safety (F&S), hatch kinematics, gaps & flushness (G&F), and product quality (PQ).
• Directed train cab and saloon system design, supporting projects through validation and industrialization phases.
• Developed and implemented vehicle integration solutions to meet customer, regulatory, and operational requirements.
• Prepared vehicle layouts and concept architecture studies for bid and pre‑development projects based on customer requirements.

Project: Tren Maya Regional Train

Industry: Rail / Rolling Stock

• Collaborated with multiple global engineering sites on the development of the Tren Maya Regional Train, managing three distinct train configurations within a single program.
• Executed end‑to‑end engineering activities covering concept design, requirement verification, special process definition, assembly sequencing, tolerance stack‑up analysis, and design reviews with suppliers and internal stakeholders.
• Led the design and development of train cab and saloon systems, guiding the project through the industrialization phase.
• Developed and implemented system integration solutions to ensure compliance with customer and operational requirements.
• Prepared vehicle layouts and concept architecture studies to support bid proposals in alignment with customer specifications.
• Led multidisciplinary vehicle system integration, ensuring seamless interaction between mechanical, electrical, and software systems to enhance train performance, reliability, and maintainability.

Project: 15 m Rear Engine Coach Bus (Multi‑Axle)

Industry: Automotive

• Led concept preparation and developed detailed design proposals for RE MAC, aligning engineering solutions with performance, packaging, and regulatory requirements.
• Conducted competitor product benchmarking, capturing service‑related issues and translating findings into design improvements.
• Validated Digital Mock‑Ups (DMU), ensuring compliance with trim gaps, clearances, flushness, and overall vehicle integration.
• Developed complete vehicle concepts, including bus body structure, architecture, and layout definitions.
• Prepared and presented technical documentation for approvals through Design and Pre‑Release Authorization Reviews (Stage‑1, Stage‑2, and Stage‑3).
• Designed chassis frame support members and integrated engine room structures, ensuring structural integrity and serviceability.
• Prepared and finalized DFMEA and DVVP for parts and systems in line with AL standards, mitigating technical and functional risks.
• Tracked and implemented BS‑VI homologation regulation updates, ensuring regulatory compliance of vehicle systems.
• Coordinated component and vehicle validation activities, including lab testing and vehicle evaluation, and successfully closed all Component Failure Reports (CFRs) prior to Stage‑3 release.
• Ensured high 3D/2D design hygiene, covering kinematics, clash detection, clearances, and mounting strategies; released final drawings through PLM systems.
• Prepared detailed installation drawings for vehicle aggregates to support prototype builds.
• Provided engineering coordination and on‑site proto build support, resolving design and assembly issues.
• Managed and mentored a five‑member engineering team, driving innovation in bus design and improving overall product reliability.

Project: Full Contract Execution – London Olympic Bus (Single & Double Deck)

Client: Alexander Dennis Limited (ADL), UK
Industry: Automotive

• Led the redesign of existing bus platforms, managing height and width modifications to meet updated customer and regulatory requirements.
• Designed the bus body superstructure in alignment with the developed chassis architecture, ensuring structural integrity and manufacturability.
• Engineered multiple bus body sections in compliance with customer specifications and homologation regulations.
• Designed and packaged electrical and electronic components (ABS, EDC, BCU) using Solid Edge, ensuring compliance with industry standards and IP protection levels.
• Collaborated with cross‑functional teams (VI, FBS, FES, VEE) to obtain system inputs and execute wiring harness routing using CATIA V5.
• Prepared detailed installation and routing drawings for wiring harnesses to support accurate design release.
• Released final 3D models and 2D drawings through PLM systems, ensuring traceability and revision control.
• Owned responsibility for understanding chassis requirements across all vehicle systems, developing concept structural designs for subsystems, and routing heating, cooling, and braking pipelines.
• Coordinated customer approvals at the concept stage, followed by task allocation to team members for detailed design execution.
• Performed quality reviews at every project phase, ensuring deliverables met customer commitments, cost, and timeline targets.
• Designed mounting structures for electrical components and optimized harness routing, balancing system constraints and variant requirements.
• Supported development of five vehicle variants, starting with A40 (40‑seater + driver) and later evolving into CNG, Electric Vehicle (EV), A35 (35‑seater), and Articulated Bus configurations.

Project: Light Combat Aircraft (LCA) & Intermediate Jet Trainer (IJT)

Industry: Aerospace
Organization: Hindustan Aeronautics Limited (HAL)

• Performed 3D part modeling, drafting, and assembly of wing structural components using CATIA V5R19, adhering to aerospace design standards.
• Developed production and design drawings for electrical components, mechanical parts, and composite wing structures, ensuring accuracy and manufacturability.
• Supported wing design and composite structure development, collaborating with senior design engineers and production teams.
• Provided production support, resolving design clarifications and ensuring smooth transition from design to manufacturing.
• Ensured compliance with aerospace drawing standards, tolerances, and configuration control throughout the design lifecycle.