Summary
Overview
Work History
Education
Skills
Websites
Accomplishments
Certification
Languages
References
Timeline
Generic

VIJAY KUMAR MALAGI

Novi

Summary

  • Software Validation Technical Lead, SCRUM Master, HIL Validation Engineer, and Systems Engineer with 8 years of experience testing ZF 8- and 9-speed transmissions, electrified motor inverters, and conventional and hybrid powertrain HIL validation, as well as test automation and development experience.
  • Proven leadership abilities, with experience leading an international team of 16 software V&V engineers, successfully executing multiple DV and PV regression test cycles for several motor inverter programs at Dana.
  • Strong working knowledge of dSPACE SCALEXIO HILs and automotive powertrain systems, such as planetary gear sets (ATs), CVT, DCT, hybrid systems (P0, P1, P2, P4), electric motor inverters, and IC engines.
  • In-depth knowledge of communication protocols, including CAN, CAN FD, CAN-DPT, and LIN, along with CCP and XCP implementations, J1939, ISO 14229 (UDS), and OBD testing. Experienced in working with various electronic control modules, such as MCU, ECM, TCM, BCM, ESM, GSM, AGSM, SCCM, and CAN Gateway.
  • Solid understanding of industry standards and methodologies, including ISO 26262 (functional safety), ASPICE (Automotive SPICE), and Agile development practices.

Overview

9
9
years of professional experience
1
1
Certification

Work History

HIL Systems Engineer

Dana Incorporated
02.2021 - 04.2025
  • Served as the Software V&V Technical Lead, managing, planning tasks for a team of 16 engineers on JIRA and fulfilling Scrum Master responsibilities as well for software validation of electrified motor units across key motor inverter projects.
  • As ODMS process engineer, crafted templates, guidelines, and checklists for validation activities at SWE4, SWE6, SYS4 and SYS5, fully aligned with ISO 26262 and ASPICE requirements on Stages by Method Parks.
  • As a proof of concept, crafted a test-strategy framework on Polarion ALM for the Test Design Specification that defines Inspection, Review, Test, and Demonstration methods-now adopted across all Dana projects.
  • Successfully implemented the solution for Variant Management and Versioning of test cases using dSPACE SYNECT, resulting in reutilization of test cases between several motor inverter programs in Dana, substantially reducing the time needed for test development and automation for each individual motor inverter project.
  • As proof of concept, implemented the CCP/XCP connection for the dSPACE HIL bench on ControlDesk using Vector CAN Case, to solve the write and read issue for internal software parameter.
  • As part of SWE 1 activity, analyzed and approved the motor control software requirements for Dana motorinverters and provided necessary change feedback to the software and system engineers.
  • Represented software VnV team in the big room planning, met EPM's, verified and approved the validation requests, aligned with the cross functional team to get updated SW requirements, HSI's, calibration data, Motor ACME results.
  • Updated the MATLAB-Simulink motor model, hardware PIN connections, RTI CANMM, calibrated the transfer functions for motor sensors, built the model on ConfigurationDesk. Finally, performed smoke test for HIL bench commissioning.
  • Performed pin mapping for motor control board to dSPACE HIL, for sensors such as motor coil temperature, phase current, ambient temperature, HV Battery, EMI temperature, resolver.
  • Developed several Synchronized libraries on SYNECT for motor control testing and AutomationDesk python libraries which drastically reduced the testing time.
  • As SW VnV technical lead, created DVPnR's, test plan, strategy and test run on Polarion for DV and PV regression testing.
  • Served as a SCRUM Master-led daily stand-ups, allocated tasks in JIRA for 16 engineers, and facilitated sprint retrospectives and backlog refinement sessions with stakeholders.
  • Analyzed and validated the motor control software requirements and developed test design by employing equivalence class method, and also designed test cases on Polarion for features such as state machine, cooling management, derating, HVIL, discharging, advanced signal acquisition, DTC management, basic signal acquisition, high voltage battery.
  • Automated and validated motor control test cases on SYNECT and AutomationDesk.
  • Led the regression testing loop by validating the motor control features using ControlDesk, ODIN, AutomationDesk and Canape. Updated the test run on Polarion and published the test plan and test report on AZURE.
  • Led cross-team triage meetings to assess and prioritize JIRA-tracked software problems, pinpointing high-risk items that might delay the release.
  • Transformed high-level requirements into detailed low-level requirements for the traffic-control module and motor-control state machine, maintaining full traceability and coverage in Pixref.
  • Designed and validated Stateflow logic in MATLAB Simulink for the traffic-control module and MCU state machine, testing each low-level requirement before integrating the finalized Stateflow into the overall Simulink model.

Transmission Systems Validation Engineer

KPIT Technologies Inc.
05.2017 - 02.2021
  • Company Overview: End Client: Stellantis (Fiat Chrysler Automobiles), Auburn Hills, MI
  • Analyzed the Core Shift Manager Component requirements for both 8-speed and 9-speed tPMBD (Transmission - Physics Model Based Development) programs.
  • Developed test scenarios for the 21 KL 3.2L 948TE tPMBD and 21 WL 3.6L 8501RE programs on Rational Quality Manager (IBM's ALM tool).
  • Prepared the test bench on the dSPACE GEN4 HIL for validation of CFTS's (Component Functional Technical Specifications) by connecting the ECM, TCM and DTCM to the HIL and flash them with the development software using INCA and CDA.
  • Automated the test cases on SYNECT and validated the test cases using AutomationDesk and ProveTech.
  • Analyzed and developed test procedures and test equipment's on DVP&R for various FCA vehicle lines for both HIL and vehicle testing, by referring the NAFTA, LATAM and EMEA requirement documents on DOOR's.
  • Interacted with the systems engineers, calibrators, and HIL model engineers to understand and develop test strategies for new product line and new vehicle features.
  • As HIL commissioning lead met, with respective project chiefs to discuss about future vehicle software validations, changes in vehicle functionalities, calibration changes, new software, and hardware implementations.
  • As VnV SME validated vehicle systems such as, Gear Changing Commands for AT, Brake Transmission Shift Interlock, Gearbox Drivability management, Automatic Transmission Management, Transmission Vehicle Hold Management, Hill Descent Control Management on dSPACE HIL's and vehicle using Provetech, INCA, CDA, CANoe, CANalyzer and documented the results on DVP&R. Also, calibrated necessary ECM and TCM parameters when necessary.
  • Prepared the HIL test bench for the assigned validation, by connecting the necessary electric harnesses, control units (ECM, TCM, HCP, AHCP) and real time hardware components (DTCM, Gear module, IPC's, BSG's, breakout boxes etc.).
  • Reported software and calibration issues on PITS and perform FMEA, attend meetings with control engineers and calibrators for issue resolution.
  • Developed smart scripts, which helped the model engineers improve the model accuracy.
  • Developed OBD test procedures for all the FCA's 8-speed transmission programs, involving electrical faults, emission related faults and driver safety related faults by referring to OBD error handler document generated using the D-Calibrator tool.
  • Validated the reactions of each diagnostic fault code, maturation time, enabling conditions and calibrations.
  • End Client: Stellantis (Fiat Chrysler Automobiles), Auburn Hills, MI

Powertrain HIL Engineer (Intern Position)

KPIT Technologies Inc.
05.2016 - 04.2017
  • Company Overview: End Client: Stellantis (Fiat Chrysler Automobiles), Auburn Hills, MI
  • Prepared the HIL for ECM software validation on various Fiat and Chrysler vehicles, then flashed ECM and TCM units with released software via INCA and an in-house diagnostic tool before validating the ECM on ProveTech.
  • Performed automated tests using HIL Automation Testing Tool (HATT) and made necessary calibration changes to the software using INCA.
  • Validated vehicle functions such as Cruise Control, Engine Torque Management, Engine Oil Temperature, Engine Speed Management and Engine Input and Output.
  • Allocated validation tasks to offshore team, resolved the queries regarding ECM software validation and updated Design Verification Plan and Report sheet after validation (DVP&R).
  • Generated Diagnostic Constant Files (DCF) and performed automated and manual open - short tests on ProveTech.
  • Consulted NAFTA charts to identify configuration-specific DTCs, then applied targeted calibration updates in INCA to clear those codes and prevent disruptions to OBD testing.
  • End Client: Stellantis (Fiat Chrysler Automobiles), Auburn Hills, MI

Education

Master of Science - Automotive Systems Engineering

University of Michigan
Dearborn, MI
04.2017

Bachelors - mechanical engineering

Visvesvaraya Technological University
Belgaum, India
06.2014

Skills

  • INCA
  • ProveTech
  • DSPACE
  • HIL
  • CANoe
  • CANalyzer
  • DC plot
  • AutomationDesk
  • ControlDesk
  • ConfigurationDesk
  • SYNECT
  • MATLAB
  • Simulink
  • CANape
  • Pisnoop
  • GIT
  • Fork
  • CDA
  • Power Cal
  • DOORs
  • Galileo
  • GAUSS
  • Polarion
  • Stages
  • ODIN
  • Python
  • JIRA
  • AZURE
  • Team leadership
  • Cross-functional collaboration
  • Variant management
  • Requirements analysis
  • Software validation
  • Test case development
  • Problem solving
  • Task prioritization
  • Testing procedure development
  • Agile methodologies
  • Requirements gathering
  • Excellent communication
  • Problem-solving abilities
  • Problem-solving aptitude
  • Test strategy
  • Project management
  • Automated testing

Accomplishments

  • Recognized for tPMBD test automation, scripted and automated test cases on SYNECT, coordinating a new HIL plant model running full loop of validation from Rational Quality Manager.

Certification

  • INCA Training

Languages

English
Full Professional
Hindi
Full Professional

References

References available upon request.

Timeline

HIL Systems Engineer

Dana Incorporated
02.2021 - 04.2025

Transmission Systems Validation Engineer

KPIT Technologies Inc.
05.2017 - 02.2021

Powertrain HIL Engineer (Intern Position)

KPIT Technologies Inc.
05.2016 - 04.2017

Master of Science - Automotive Systems Engineering

University of Michigan

Bachelors - mechanical engineering

Visvesvaraya Technological University

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VIJAY KUMAR MALAGI