Suresh Viswanathan
Jeddah,Saudi Arabia
Summary
- 18+ years of experience in the design and development of Electrical Distribution Boards, Telecom Equipment, Devices, Displays, Electro-Mechanical Systems, Food Cartridges, and a wide range of Consumer and Industrial Products.
- Expertise in materials and manufacturing processes, including Sheet Metal, Plastics, Castings, Press Tools, Jigs & Fixtures, and Special Purpose Machinery (SPM).
- Hands-on experience in electro-mechanical PCB integration, including PCB layout design and coordination with hardware and mechanical components.
- Proficient in selection and integration of protection devices (MCB, MCCB, RCBO, RCCB) based on load, voltage, current, and safety standards. S
- killed in rapid prototyping methods, including 3D Printing, SLA, CNC Machining, Vacuum Casting, and Sheet Metal Fabrication.
- Experienced in prototype testing and validation, including EMI/EMC, shock & vibration, drop, acoustics, short-circuit withstand, overcurrent protection, temperature rise, and dielectric performance.
- Strong in design quality practices such as tolerance stack-up analysis, GD&T, DFMEA, and DFM/DFA to ensure reliability, manufacturability, and compliance.
- In-depth knowledge of global standards: UL, IEC, NEMA, NEBS, VESA, ARAI, and other relevant electrical, telecom, and automotive standards.
- Proficient in CAD & PLM tools, including Creo, Inventor, CATIA, SolidWorks, Windchill, Agile, and Intralink.
- Experienced in NPI and Value Engineering (VE) project management, covering planning, scheduling, resource coordination, and cross-functional collaboration.
- Skilled in supplier and client coordination for parts manufacturing, procurement, and validation across the Asia-Pacific region (China, Malaysia), ensuring cost-effective and high-quality solutions.
Overview
20
20
years of professional experience
3
3
years of post-secondary education
Work history
SENIOR ENGINEER
BAHRA ELECTRIC
12.2022 - 09.2025
- Company Overview: Products Involved: Main/Sub Distribution Boards, Load Centers, Service Enclosures, Busbar Chambers, Switch Disconnector, Smart Meter, Mini Pillar and EV Charger Pedestal
- End-to-end design and development of Electrical Distribution Boards as per IEC 61439, ensuring IP41 to IP65 protection ratings for both indoor and outdoor applications.
- Developed sheet metal enclosures with optimized layouts for breaker mounting, busbar arrangements, and wiring space.
- Designed modular, robust enclosures for wall- and floor-mounting, maintaining clearances and accessibility in full compliance with IEC standards.
- Performed busbar design with proper sizing, creepage distances, safe clearances, and protective measures using insulators and shrouds.
- Selected breakers and components (MCB, MCCB, RCCB & RCBO), meters, relays, terminals, and communication modules in accordance with IEC 60947/60898 standards.
- Interpreted single-line diagrams and circuit lists to develop concepts and prepare prequalification samples for utility and authority approval (SEC).
- Conducted prototype development and testing, including type tests and routine tests for temperature rise, dielectric strength, short-circuit, and IP/IK verification.
- Integrated industrial design and ergonomics into AC/DC EV chargers, covering pedestals, cable management, and interface accessibility.
- Responsibilities:
TECHNICAL LEAD
HCL TECHNOLOGIES LTD
03.2018 - 11.2022
- Company Overview: Project/ Client: Microsoft Corporation, Intel Corporation, Barco Electronics, Ericsson, Sanmina, Vexata
- Products Involved: Laptops, Tablets, Doorbell Cameras, LED/LCD Displays, Projectors, Radio Devices
- Food Transport Cartridges and High-Performance Networking Switches & Servers.
- Designed and developed electronic packaged products and accessories such as laptops, tablets, displays, and radio devices.
- Engineered Blade Server Enclosures with air cooling, PSU, PDU, and AC/DC input integration.
- Built PCB assembly test fixtures using nail-bed probe systems.
- Developed food transport cartridges and pizza vending machines for Pizza Hut and Domino’s.
- Designed projector mirror mounting frames with riveting fixtures to simplify assembly.
- Created custom VESA mounts for LED/LCD displays.
- Designed enclosures in plastic, sheet metal, casted, and machined parts for prototypes and electro-mechanical interfaces.
- Verified hardware board designs (EMN/EMP) for interference, fitment, and manufacturability; defined keep-in/keep-out areas and height restrictions.
- Managed complex cable and flex PCB routing and implemented thermal solutions such as heat sinks, airflow, fans, and liquid cooling.
- Ensured signal integrity and compliance with global standards including IEC, UL, CE, NEBS, NEMA, and RoHS.
- Applied tolerance stack-up analysis, GD&T, DFMEA, and DFM/DFA to ensure reliability, manufacturability, and quality.
- Conducted prototype and pre-compliance testing including EMI/EMC, shock, vibration, drop, and acoustics.
- Created advanced skeleton 3D CAD models to support modularity and future product updates.
- Prepared and managed BOMs, GA drawings, manufacturing documents, and inspection reports.
- Coordinated with manufacturers and suppliers for design validation and production readiness.
- Responsibilities:
TECHNICAL LEAD
CHENNAI WORKS
06.2016 - 02.2018
- Company Overview: Project/ Client: Eaton Corporation
- Products Involved: Fuse Assembly Machine
- Studied requirements and specifications to align with project goals.
- Guided teams to achieve deliverables with high quality and on-time execution; coordinated with suppliers for quotations and scheduling.
- Generated concept designs, secured client approvals, and developed detailed designs.
- Designed and developed a Fuse Assembly Machine, improving automation and production efficiency.
- Engineered Jigs, Fixtures, and custom components for Special Purpose Machinery (SPM).
- Developed and integrated motors, drives, PLCs, sensors, and actuators into machinery systems.
- Ensured structural rigidity, vibration control, and precision tolerances for moving and rotating parts.
- Incorporated safety interlocks, emergency shutdown systems, and automation readiness into machine designs.
- Standardized designs by applying off-the-shelf components such as cylinders, sliding rails, and actuators.
- Selected materials strategically for strength, wear resistance, corrosion resistance, and weight optimization.
- Conducted DFM reviews and tolerance stack-up analysis to ensure manufacturability and reliability.
- Provided rapid solutions and root-cause analysis to resolve issues and ensure timely closure.
- Responsibilities:
SENIOR PROJECT ENGINEER
WIPRO TECHNOLOGIES LTD
06.2011 - 07.2015
- Company Overview: Project/ Client: Cisco Systems, Avaya Inc, Atos, NEC
- Products Involved: High Performance Data transferring Server & Switches
- Designed and developed Blade Server Enclosures (VSP9010 & 9012) with PSU, PDU modules, and AC/DC input integration.
- Engineered servers with front and rear slots and midplanes to access SF and AUX cards.
- Designed front-to-back air cooling modules with N+1 redundancy and hot-pluggable capability.
- Developed 1U, 2U, and 3U hot-pluggable server modules with liquid cooling (water) systems.
- Created customized racks (non-standard) for high-speed data transfer applications (SEQUANA).
- Designed enclosures in plastic, sheet metal, casted, and machined parts for prototypes and electro-mechanical interfaces.
- Verified hardware board designs (EMN/EMP) for interference, fitment, and manufacturability.
- Defined routing and keep-in/keep-out areas, height restrictions, and Gerber release requirements.
- Collaborated with hardware and thermal teams to implement appropriate design updates.
- Managed complex cable and flex PCB routing and implemented thermal solutions.
- Selected and integrated off-the-shelf components including heat sinks, fans, locks, handles, and fasteners.
- Ensured signal integrity and compliance with IEC, UL, CE, NEBS, NEMA, and RoHS standards.
- Applied tolerance stack-up analysis, GD&T, DFMEA, and DFM/DFA to ensure fit, function, reliability, and manufacturability.
- Conducted prototype and pre-compliance testing including EMI/EMC, shock, vibration, drop, and acoustics.
- Responsibilities: Responsibilities:
DESIGN ENGINEER
TECH MAHINDRA
11.2010 - 05.2011
- Company Overview: Project/ Client: Schneider Electric
- Products Involved: Industrial UPS
- Designed and developed industrial UPS enclosures (Galaxy 6000), improving ergonomics and aesthetics while meeting industrial standards.
- Delivered electro-mechanical product designs (sheet metal and plastic components) that enhanced reliability and reduced assembly issues.
- Led re-engineering of an electro-mechanical components, achieving improved performance and extended product lifecycle.
- Created concept and detailed designs following sheet metal design guidelines, optimizing manufacturability and cost.
- Produced manufacturing drawings with GD&T, ensuring precision and compliance with tolerance requirements.
- Conducted DFM reviews and tolerance stack-up analysis, reducing rework and improving first-pass success.
- Prepared accurate Bills of Materials (BOMs), streamlining procurement and reducing delays.
- Performed interference checks in assemblies, preventing design conflicts and reducing prototyping iterations.
- Responsibilities:
DESIGN ENGINEER
SPM INDIA LTD
06.2009 - 11.2010
- Company Overview: Project/ Client: Honeywell Technologies, Mahindra & Mahindra
- Products Involved: Turbo Charger Assembly Machine & Engine Head Leak Testing Machine
- Studied requirements and specifications to align with project goals.
- Guided teams to achieve deliverables with high quality and on-time execution; coordinated with suppliers for quotations and scheduling.
- Generated concept designs, secured client approvals, and developed detailed designs.
- Designed and developed a Fuse Assembly Machine, enhancing automation and production efficiency.
- Engineered Jigs, Fixtures, and custom components for Special Purpose Machinery (SPM).
- Developed and integrated motors, drives, PLCs, sensors, and actuators into machinery systems.
- Ensured structural rigidity, vibration control, and precision tolerances for moving and rotating parts.
- Standardized designs using off-the-shelf components such as cylinders, sliding rails, and actuators.
- Selected materials strategically considering strength, wear resistance, corrosion resistance, and weight optimization.
- Conducted DFM reviews and tolerance stack-up analysis to ensure manufacturability and reliability.
- Responsibilities:
DESIGN ENGINEER
ARJUN MOTORS PVT LTD
02.2008 - 03.2009
- Company Overview: Products Involved: 10+1 and 9+1 Luggage Carrier-to-Passenger Carrier Vehicle (Virgo)
- Designed and developed vehicle rear cabins with reinforced structures for enhanced durability.
- Worked on next-generation 4-wheeler rear cabins, including interior and exterior components.
- Developed 10+1 and 9+1 seating configurations with integrated safety features in compliance with ARAI and VRDE standards.
- Created detailed part and assembly drawings for submission and approval by authorities.
- Ensured structural rigidity, vibration control, and precise tolerance management for moving and rotating components.
- Selected materials strategically based on strength, wear resistance, corrosion protection, and weight optimization.
- Conducted DFM reviews and tolerance stack-up analysis to ensure manufacturability, performance, and long-term reliability.
- Responsibilities:
TOOL DESIGNER
NANDI TECH INC
01.2006 - 01.2008
- Company Overview: Products Involved: Press Tools, Jigs & Fixtures, Molding Dies
- Generated concepts for press tools and developed strip layouts for sheet metal components.
- Performed press tonnage calculations to ensure optimal tool design and performance.
- Designed jigs and fixtures for sheet metal automotive components.
- Designed molding dies for plastic components.
- Created detailed manufacturing drawings and coordinated with vendors for timely execution.
- Interfaced with tool room teams and suppliers for tool manufacturing, sampling, and troubleshooting.
- Responsibilities:
Education
Diploma - Tool & Die Making
Board of Technical Education
Tamil Nadu 01.2002 - 01.2005
Languages
English
Advanced
Tamil
Native
Arabic
Beginner
Timeline
SENIOR ENGINEER
BAHRA ELECTRIC
12.2022 - 09.2025
TECHNICAL LEAD
HCL TECHNOLOGIES LTD
03.2018 - 11.2022
TECHNICAL LEAD
CHENNAI WORKS
06.2016 - 02.2018
SENIOR PROJECT ENGINEER
WIPRO TECHNOLOGIES LTD
06.2011 - 07.2015
DESIGN ENGINEER
TECH MAHINDRA
11.2010 - 05.2011
DESIGN ENGINEER
SPM INDIA LTD
06.2009 - 11.2010
DESIGN ENGINEER
ARJUN MOTORS PVT LTD
02.2008 - 03.2009
TOOL DESIGNER
NANDI TECH INC
01.2006 - 01.2008
Diploma - Tool & Die Making
Board of Technical Education
01.2002 - 01.2005
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