Thomas Varghese

Directed the end-to-end development and market introduction of the award-winning CleverCharge Level 2 EV charger, working hand-in-hand with diverse teams to align with customer needs and business goals. • Spearheaded the end-to-end development and market introduction of the award-winning CleverCharge Level 2 EV charger, earning the 2025 CES Innovation Award for design and functionality. • Led cross-functional teams (electrical, mechanical, software, firmware) through the complete product lifecycle, from concept to mass production. • Navigated complex UL and FCC compliance and certification, ensuring timely market entry. • Integrated AI-enhanced features including personalized charging profiles, proactive reminders, optimized charging schedules, and comprehensive home EV management. • Implemented Agile methodologies, optimizing timelines and accelerating time-to-market. Improved CleverCharge product reliability by 15% using 8D methodology, robust testing, and iterative design. • Orchestrated supply chain management, reducing material costs by 10% while maintaining quality. • Led risk management initiatives, ensuring project delivery within scope, budget, and schedule. • Defined product specifications and user experience, ensuring easy installation, user-friendliness, and compatibility with all EV types, including Tesla (with OBD-II). • Facilitated seamless communication across teams and stakeholders, aligning with business objectives and customer needs.

Managed product lifecycle and collaborated with diverse cross-functional teams to ensure products met customer expectations and business objectives. • Achieved over $2.7 million dollars in cost savings, by using root-cause analysis to identify and resolve multi Electronics Control Unit (ECU) software glitch by enabling Over Air Software (OTA) updates for over 1,800 BlueCruise production vehicles. • Reduced Toll leakage rates from 30% to 0%, by reaching ~100% vehicle detection success rate using novel Tolling C-V2X application feature. • Obtained ratings of 8-10 ratings in System Usability and Net Promotor scores from 93% of clinic participants, by leading development of Tolling and Traffic light pre-emption Human Machine Interface (HMI) screen feature.

Led and managed multi-million-dollar vehicle programs, including battery electric vehicles, ensuring on-time and on-budget delivery through expert program management and strategic collaboration.. • Realized $50M annual enterprise costs savings, and achieved 95% improvement in parts availability to support pre-production builds, by developing and deploying Best-In-Class process to establish and maintain prototype BOM for each vehicle configuration. • Achieved 35% reduction in BOM creation time and related errors, by deploying next generation application across all programs globally and improving authoring efficiency for customers. • Executed Best-In-Class cost/weight/tooling change management process, that achieved 85% stakeholder satisfaction rate and 30% reduction in cycle time for financial milestones.

Designed and developed HMI systems for Driver Assistance Features on Instrument Cluster/Center Stack digital displays. • Improved user experience, increased safety, reduced driver errors, and enhanced brand perception by producing intuitive and visually appealing HMIs of Driver Assistance Features (Active Park Assist, Trailer Back-up Assist, Park Distance Control, and Camera). • Supported 67% increase in adoption rates for SYNC HMI systems, by spearheading development and implementation of SYNC Gen2 and SYNC Gen3 HMI system.

Led the strategic implementation of Teamcenter PLM and created data management governance frameworks to improve product development and manufacturing processes. • Enabled first-time enterprise-wide central BOM management for 12,000 global users, by leading Advanced Bill of Materials (AVBOM2) development through Agile software development practices. • Delivered 70% reduction in product design issues, by enabling digital design reviews in Teamcenter. • Reduced time required to define part-to-feature complexity by 90%, by designing and releasing easy to use configuration worksheet toolset. • Minimized development time, cost and investment, while maximizing commonalities, by pioneering development and deployment of Global Product Development System (GPDS) process.

Led technical teams in the maintenance and operation of advanced radar and missile platforms.