Gustavo Alejandro Aguilar Anaya

• Lead diagnostic architecture and hardware validation for high-volume EV manufacturing operations. Oversee sub-assembly test systems and ensure validated subcomponents meet functional and diagnostic requirements throughout the assembly process. Partner with suppliers to define technical specifications and develop next-generation testers for future vehicle platforms.
• Support and maintain sub-assembly testers Front End Module, Door and IP testers as well as the End-of-Line (EOL) diagnostic systems to ensure production stability
• Define diagnostic detection strategies through DFMEA and PFMEA to ensure proper fault containment at each manufacturing stage.
• Ensure diagnostic consistency and coverage across multiple vehicle platforms.
• Collaborate with hardware, firmware, software, and manufacturing teams to implement scalable diagnostic solutions.
• Validate diagnostic logic and fault handling prior to production release to prevent field escapes.
• Lead root cause investigations related to diagnostic gaps, false failures, and hardware validation discrepancies.
• Develop documentation and technical standards to support production and service readiness.
• Experience with DSA Test Systems, including automation.
• Key Contributions:

Improved diagnostic robustness and reduced unnecessary EOL false failures.

Strengthened traceability between FMEA outputs and manufacturing test implementation.

Increased production stability through structured diagnostic governance.

Collaborated with cross-functional teams to streamline engineering processes and improve product development timelines.

• Responsible for engineering, root cause analysis, onsite support, and validating automotive software and electrical integration within the production environment. Serve as the single point of contact for new software implementation issues. Act as the technical liaison between software and control teams in California and Casa Grande Factory.
• Led ECU software integration and validation at the plant level.
• Evaluated manufactured ECUs, sensors, and actuators using Vector CANoe/CANalyzer to ensure compliance with specifications.
• Diagnosed and resolved CAN communication and integration issues affecting production.
• Conducted structured root cause analysis for software-related failures.
• Recommended design and process improvements to enhance production reliability.
• Reported and tracked assembly and integration metrics to assess sustainability of new software implementations.
• Key Contributions:

Reduced recurring software-related production disruptions.

Improved diagnostic efficiency and fault isolation within manufacturing.

Enhanced software validation processes prior to mass production release.

Executed the launch of Lucid Air Sapphire and Gravity.

• Acted as Technical Office R&D liaison between Audi Germany and VW Technical Development for conventional and hybrid propulsion systems. Led engineering change implementation and failure containment strategies for powertrain issues identified during assembly and Quality Gate validation, safeguarding production stability. Owned powertrain software implementation, configuration control, and release readiness for series production. Drove resolution of manufacturing-impacting software issues through cross-functional coordination with development and plant teams.
• Validated and calibrated powertrain software for gasoline, diesel, and hybrid vehicles.
• Supported integration of high-voltage components including Battery Junction Box, Power Electronics, and Battery Management Systems.
• Performed pre-series prototype validation at the assembly plant and test track.
• Conducted vehicle communication diagnostics using CAN and FlexRay.
• Improved automated engine test systems to increase reliability and detection capability.
• Provided on-site technical support for hardware and software integration issues.
• Collaborated with the Employer Branding team to impart EV conferences for universities.
• AUDI/VW Systems: KVS - TiREX - System4 - IDEX- Connect
• Key Achievements:

Supported launch of the first Hybrid Q5 produced in Mexico for the global market.

Reduced automated engine test issues across gasoline, diesel, and hybrid configurations.

Evaluated 125 prototype vehicles prior to shipment to Audi Powertrain Development in Germany.

• Led powertrain failure analysis for fully assembled vehicles, investigating issues identified during test track evaluations. Conducted structured root cause analysis, documented technical findings, and implemented corrective actions to improve product quality and reliability. Completed a one-year technical training program at the Germany headquarters and gained hands-on experience with advanced diagnostic and mechanical tools.
• Led Powertrain Quality Gate investigations for the Audi Q5 project.
• Coordinated technicians and test equipment to ensure structured failure analysis.
• Developed test cycles for improved failure detection at the test track.
• Documented and presented findings in cross-functional engineering reviews.
• Supported field issue resolution at dealers and ports.
• Key Achievements:

Contributed to the successful launch of the new generation Audi Q5.

• Managed sales performance for 13 dealerships in Northern Mexico by developing and executing targeted wholesale and retail strategies while analyzing competitive market trends to optimize inventory turnover and volume mix.
• Monitored inventory levels to ensure optimal volume, mix, and turnover.
• Implementation of a technical approach using vehicles’ characteristics to gain market against the competition
• Analyzed market conditions and competitive trends to support business planning.
• Key Achievements:

Increased regional sales by 5%.

Reduced vehicle inventory in 9 of 13 dealerships by an average of 10%.

• Powertrain Quality Manager, serving as the primary liaison between dealerships, service departments, customer care centers, and manufacturing operations, managed engine and transmission warranty performance using structured failure analysis methodologies such as Pareto, Ishikawa, and FMEA. Additionally, they led cross-functional problem resolution efforts to support product launches and quality readiness reviews.
• Key Achievements:

Reduced IPTV (Incidents per Thousand Vehicles) for GMT900 truck platforms.

Improved warranty response time from 5 days to 2 days.

• Development and validation engineer responsible for vehicle-level thermal management systems, including engine cooling, HVAC, and PTC architectures, ensuring compliance with GM performance, safety, and efficiency standards.
• Calibrated engine cooling systems and supported refinement of thermal control strategies to optimize propulsion and cabin performance.
• Led vehicle-level thermal validation under extreme environmental conditions, including climatic wind tunnel and proving ground testing.
• Performed data acquisition and thermodynamic analysis for HVAC, PTC, and propulsion cooling systems to balance cabin comfort with powertrain efficiency.
• Validated system performance against Vehicle Technical Specifications (VTS) during development and pre-production phases.
• Conducted structured root cause analysis to resolve performance gaps identified during testing and launch readiness activities.
• Collaborated with Global Propulsion Systems and Aerodynamics teams to improve thermal calibration and system integration.
• Key Projects:

Captiva Global – Cooling Engineer MY10/11

Lambda Crossover – Cooling & Thermal Engineer MY11–13

Buick Verano – Powertrain Cooling Engineer MY12/13