Ajay Virmalwar

Led multinational EV vehicle programs supporting Europe and North America regions for Renault & Stellatis Group. Full vehicle development from concept through prototype build via digital validation. Ensured designs met styling, tooling, manufacturing process constraints, packaging requirements, and GD&T conditions. Investigated prototype test failures, identified root causes, and proposed countermeasure solutions to ensure timely resolution.
Drove physical-to-digital correlation for regulatory and performance load cases, strengthening confidence in simulation-driven validation. Ensured compliance with global safety and regulatory standards including ENCAP, GNCAP, and FMVSS across regional markets.
Managed cross-functional teams, overseeing people performance management, skill development, and fostering a culture of excellence, collaboration, and customer partnership.

Worked closely with OEM TML production facilities, gaining direct exposure to the manufacturing and assembly cycle from component integration to final vehicle build. Experienced the touch and feel of actual products, strengthening understanding of design-to-production transitions.
Witnessed and supported physical testing phases including bench tests, subsystem and full-vehicle crash tests, NVH & SAR evaluations, proving ground runs, torture track durability, and environmental validation.
Enhanced expertise in bridging virtual and physical validation, ensuring simulation accuracy and confidence in product performance. Leveraged this exposure to improve digital validation workflows, aligning CAE results with real-world testing outcomes.

Spearheaded JLR ODEC engagement to the next level, expanding the team to 100+ engineers across diverse CAE performance domains. Built capabilities not only in core areas but also in niche, cutting-edge technologies such as Squeak & Rattle (SAR), Water Wading, Paint Bake Simulation, Sand Dune Impact, High Frequency Noise (SEA) simulation, and Virtual RLD measurement.
Pioneered automation initiatives to improve workflow efficiency, boost productivity, and streamline reporting. Executed cost and weight reduction projects, delivering measurable value to product development.
Formulated and implemented a strategic roadmap to drive team growth, profitability, and alignment with customer objectives. Oversaw team performance management, fostering a culture of excellence, collaboration, and customer partnership.

Leadership of building a full-fledged Body CAE team from the ground up, scaling from a small group to 40+ engineers. Established capabilities across multiple CAE performance attributes including Model build, Crash, NVH, Strength & Durability, and CFD. Pioneered the formulation of a strategic roadmap to drive team growth, enhance profitability, and align with customer objectives.

Oversaw team performance management, fostering a culture of excellence, collaboration, and delivery consistency. Strengthened customer partnerships through proactive engagement and high-quality technical delivery.

Later, at Chrysler ODC, I led the Strength & Durability analysis team supporting design & development of Jeep & Truck group. My work spanned linear, non-linear strength & fatigue analysis of critical components, including side steps, battery tray assemblies, brake systems, closures, and pickup truck cabins & box structures, ensuring designs met stringent durability and fatigue life design DVP targets. I also conducted parent metal and spot weld & seam weld fatigue life calculations, aligning structural integrity with standard operating requirements.

Joined GE Transportation Systems as a CAE Structural Analyst, driving high-fidelity simulations for locomotive cab structures— including Engine, Radiator, and Auxiliary cabs, Engine integrated front end, Oilpan, DC Traction motor frame - to achieve cost- and weight-effective structural designs. Advanced to Lead Engineer, where I analyzed performance targets, proposed countermeasure solutions, and collaborated with design teams to implement optimized design solutions. Moreover build automation techniques for full cab-level model building and report generation, significantly reducing manual effort and enhancing efficiency across engineering workflows.
I am a DFSS Six Sigma Green Belt certified.

Started my professional journey at ARAI in 1995 as a Research Engineer, specializing in CAE-driven Durability & NVH simulations of various automotive components to sub-systems, for leading Automotive OEMs. Contributed to long-term, ministry of industry -sponsored research projects advancing national automotive standards. Progressed to Project Engineer role, where I led simulation programs, managed cross-functional teams, and strengthened OEM partnerships through technical delivery and project leadership.