KUMARESH

Senior Embedded Systems & Functional Safety Engineer
MalePre-sales technical supportLive in SingaporeNationality
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Summary

Results-driven Senior Embedded Systems & Functional Safety Engineer with nearly 9 years of automotive experience across Tier-1 suppliers (BorgWarner, Continental, Visteon). Deep expertise in full embedded software lifecycle — requirements analysis, architecture design, C/C++ implementation, and rigorous unit/integration testing — for powertrain inverter and intelligent cockpit platforms. Proven ability to lead cross-functional safety teams, interface with OEM customers (Mercedes-Benz), and drive ASIL B/C-compliant AUTOSAR Classic software architectures. End-to-end embedded SW ownership — from requirements analysis and architecture design through implementation, unit/integration testing, and software release, with full accountability across the delivery lifecycle. • CI/CD and Agile delivery experience — active contributor to Jenkins-based CI/CD pipeline setup, Git branching strategy, and cross-functional scrum collaboration across distributed engineering teams. • Dual competency in both safety process and embedded implementation — in addition to FSE certification with hands-on AUTOSAR Classic, MCAL, and software architecture skills. • Cross-functional leadership — experience driving global template standardization, cross-site safety process deployment, and supplier safety management. • Continuous learning mindset — active upskilling in Machine Learning (Coursera 2025) and software engineering (C++ Nanodegree) to stay ahead of automotive software trends.

Work experience

  • Senior Embedded Systems & Functional Safety Engineer

    BorgWarner
    2021.08-Current(5 years)
    1. Drove full embedded SW lifecycle — requirements analysis, SW architecture, C/C++ implementation and verification — for safety-critical ASIL B/C inverter ECUs on ARM SoC platforms per ISO 26262 Part 6. 1. Developed AUTOSAR-compliant Application SW for Active Discharge, Phase Current Sensing and Resolver Qualification using Simulink and Davinci Developer; implemented IoHwAb and CDD interfaces for sensor devices (ADC, DMA, SPI). 1. Architected multi-core AUTOSAR Classic embedded software — integrating BSW, MCAL (ADC, DMA, SMU, GTM) and OS abstraction across ASIL and QM partitions using Electrobit TRESOS and Vector Davinci Configurator. 1. Configured and integrated MCAL peripheral drivers (I2C, SPI, UART with DMA) for sensor and actuator interfaces; performed MCU/MPU resource profiling and validated peripheral configurations on target hardware. 1. Executed static code analysis (Polyspace, MISRA-C) and structural code coverage verification (MC/DC, statement, branch via TPT) to fulfil ISO 26262 software verification objectives; maintained zero-blocker software quality gates. 1. Led CI/CD pipeline setup and maintenance using Jenkins and Git — establishing automated build, static analysis and test workflows; drove continuous integration across distributed scrum teams. 1. Performed Software Release and Integration activities — coordinating solution demo sessions, preparing release notes, and managing software branching strategy (Git) for multi-variant product lines. 1. Performed Supplier Safety Analysis for park lock actuators — evaluated ASIL decomposition, prepared supplier requirements and supported HW safety metrics (HWEER, DC, SPFM, LFM) verification. 1. Led global cross-company initiative to create a standardized SW-DFA template; maintained full requirements traceability in Polarion linking safety requirements from system level through implementation and verification per ASPICE CL2. 1. Supported successful vehicle homologation and motor dynamometer testing — performed real-time on-site issue analysis; interfaced directly with OEM customer teams to resolve complex integration issues effectively.
  • Feature Owner – Touch Driver │ Safety & Security Engineer

    Continental
    2019.12-2021.08(2 years)
    1. Developed high-quality touch driver modules for Intelligent Cockpit (IPC) platforms, improving touch sensitivity and accuracy; designed state machines for touch/display mode transitions. 1. Designed and executed FMEA for touch subsystem; developed Functional Safety Concepts for display, acoustics, CAN end-to-end protection and telltales. 1. Integrated MCAL from silicon manufacturers; developed and maintained I2C and SPI firmware for multi-display product variants; configured BSW modules (Watchdog, Diagnostics/DTC). 1. Led functional safety integration test and release management across multiple car-line variants; supported internal functional safety assessments and supplier audits. 1. Implemented touch encryption security features (SHE, VKMS algorithms); resolved CERT-C violations to enhance code quality and security posture.
  • Member of Technical Staff

    HCL Technologies
    2019.03-2019.11(9 months)
    1. Implemented J1939 diagnostics and speaker diagnostics; emulated EEPROM functionalities in flash memory; integrated RTOS with Infineon low-level drivers and configured MCAL via Davinci Configurator.
  • Embedded Software Engineer

    Visteon Corporation
    2016.11-2019.03(2 years)
    1. Module test owner for Ethernet; developed integration test framework and automated manual test cases in CANoe — achieving 70% reduction in man-hours for regression testing. 1. Reviewed and maintained project records in Doors NG for ASPICE compliance; developed VBA macros to check RQM–Doors NG linkage; created project tracking dashboards in RTC. 1. Supported ASPICE Level 3 compliance for JLR program — awarded Silver Award for contribution to successful audit.

Projects

  • 2016.01-Current(11 years)
    Powertrain Inverter — BorgWarner (2021–Present) • Delivered embedded software for ASIL B/C inverter ECU on ARM SoC — owning requirements analysis, AUTOSAR Classic BSW/MCAL architecture, C/C++ implementation, and software verification (MC/DC, static analysis) across the full development lifecycle. • Performed Safety Integration and Qualification test at vehicle level to ensure ISO 26262 compliance, covering 95% of safety-critical requirements for extended period of 6 months in Korea and China. • Resolved critical Nexperia component obsolescence: re-executed FMEA/FTA/DFA, validated ASIL B/C hardware metrics (SPFM, LFM, DC) remained compliant — avoiding project delays of 3+ months. • Resolved critical external watchdog EE system checkout issue during vehicle integration — received Spot Recognition Award (Nov 2021) from BorgWarner leadership. • Established global SW-DFA template adopted by distributed safety teams across multiple sites, standardizing analysis methodology and reducing review cycles. Intelligent Cockpit Platform — Continental (2019–2021) • Owned touch driver feature from design through safety integration for multi-display variants — delivered across car-line derivatives with zero field escapes during release cycles. • Implemented SHE/VKMS touch encryption — enhanced cybersecurity posture for cockpit subsystem in line with emerging ISO/SAE 21434 requirements. • Led safety integration testing and release management for 4+ car-line variants simultaneously, maintaining ASPICE-compliant traceability throughout. JLR Cluster Program — Visteon (2016–2019) • Developed automated test framework in CANoe for Ethernet module validation — 70% reduction in regression test man-hours, enabling faster release cycles. • Key contributor to Visteon's ASPICE Level 3 compliance audit for JLR — ensuring full traceability between RQM and Doors NG; awarded Silver Award for audit success (Jun 2018). AI INITIATIVE Power Switch Process Analytics Chatbot with LLM Feedback Loop – BorgWarner (Jan 2025 – March 2025) • Developed an end-to-end chatbot (Python FastAPI + LLaMA3) with ETL pipelines (Jenkins + MS SQL Server) to automate test data collection, SQL query generation, and analysis. • Integrated interactive dashboards and LLM narrative summaries, fine-tuning LLaMA3 with QLoRA to improve SQL accuracy and reduce latency for real-time insights.

Educational experience

  • Anna University, India

    Electronics & Communication Engineering
    2012.09-2016.07(4 years)
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