Breaking down silos: the future of electronical-electronic co-design in cable and harness engineering

In a recent episode of the Printed Circuit Podcast, host Steph Chavez sat down with Erica Van Berkum, a leader in the Capital integrated electrical solution product management team at Siemens, to discuss the pressing challenges and emerging solutions in electrical-electronic co-design, particularly in the areas of cables and harnesses.

Van Berkum started her career over two decades ago in wire harness design with companies like Yazaki and Nissan. After starting her career at Siemens with large-scale deployments of Capital, she currently works in the intersection of systems requirements design, harness design, and manufacturing.

Working in silos

One of the biggest hurdles in electrical-electronic co-design is the lack of cross-functional visibility. Engineering teams often work in silos, failing to account for how changes in one area affect the entire system. This disconnection leads to inefficiencies, misalignments in design, and costly iterations.

“I think it all stems down to silos. We still see a lot of people working in silos,” Van Berkum explained. “That causes a lack of visibility of changes, both upstream and downstream, in the design. Information isn’t coming as consistently or frequently as it should.”

She emphasized how mechanical engineers, for example, may make small adjustments to a component or a connection point, thinking it doesn’t affect the electrical team. In reality, these modifications impact routing, wire length, voltage drops, and electromagnetic compatibility (EMC/EMI), leading to unexpected design failures.

The integration of digital tools and system

To overcome these challenges, digital tools and system integration play a crucial role in modern engineering workflows. Siemens’ Capital software is designed to enable seamless collaboration by providing real-time visibility into design changes and their implications across different engineering disciplines.

“You need to visualize and understand the implication of those requirement changes on downstream designs,” Van Berkum said. “That traceability is vital for safe and secure EE system designs. It allows engineers to move away from working in silos and instead see how their decisions impact the broader system.” Another key solution is implementing a digital thread, ensuring that all teams work with the most up-to-date design data in real-time. This approach eliminates communication delays and minimizes the risk of errors caused by outdated or conflicting information.

Cultural resistance

Beyond technical solutions, cultural resistance to change remains a significant barrier in the industry. Many companies are hesitant to adopt new technologies, preferring to stick with legacy processes that have been in place for decades.

“The sad thing is, the culture of this still exists of ‘I don’t want to make the change because I’m okay with the level of success we’re having and it’s good enough,’” Chavez said. “But when I see that companies are leaving money on the table by not evolving with the tools and industry capabilities, it is disconcerting.”

Van Berkum noted that leadership plays a crucial role in driving change. Many organizations operate with outdated workflows simply because they are comfortable with the status quo.

“They choose to let their business units or groups operate in the same systems they’ve always used because they’re comfortable,” she said. “They’re used to the software, or they know the person who worked on it before. But how are they really challenging themselves to get to the next level?”

Interestingly, the younger generation of engineers may hold the key to breaking these silos. Fresh minds bring new perspectives, adaptability, and a willingness to innovate.

“I don’t want to say ‘corrupted’—but they’re not contaminated in the sense that they’re coming in raw, with fresh ideas,” Chavez explained. “But the old guard is in place, and it’s like ‘This is the swim lane you stay in; we’ve been doing this for 40 years and have been very successful.’ But what if we could be even more successful by evolving?”

This resistance to change is often seen in automotive and aerospace industries, where legacy systems dominate. However, the need for greater flexibility, efficiency, and integration is pushing companies to rethink their approach to electrical-electronic co-design.

Key strategies to overcoming resistance

Change is difficult, but proactive strategies can ease the transition. Van Berkum identified three key steps to overcoming resistance:

1. Clear communication of the ‘why’ – Engineers need to understand the value of the change. Whether it’s a 5% increase in efficiency or a 10% reduction in costs, teams must see the tangible benefits of adopting new methodologies.
2. Proactive training and pilot programs – Organizations should invest in training their teams on new tools and processes before full-scale implementation.
3. Leveraging subject matter experts (SMEs) – Experienced engineers should guide their peers through transitions acting as change agents to bridge knowledge gaps.

“You’ve got to manage that balance,” Van Berkum emphasized. “When rolling out change, you’ll see a dip in productivity as people scale up and adapt. But if leaders communicate the ‘why’ behind a change, teams will be more willing to embrace it.”

One of the most persistent challenges in adopting new design methodologies is cost. Many companies are reluctant to invest in process improvements if they don’t see immediate financial returns.

“I’ll tell you from my recent experience in aerospace, the biggest hurdle was ‘Who’s going to pay for it?” Chavez said. “Project managers say, ‘I have my budget, and I want to stay within my target.’ And the end customer says, ‘I’m not paying you to improve your process; I’m paying you to deliver the best product at the lowest cost.’”

The benefit of modern digital solutions

To ensure efficient co-design and seamless collaboration, companies need to adopt modern digital solutions like within the Siemens’ Xcelerator portfolio, which enables you to have instantaneous design changes, automated scenario testing, and seamless integration across many domains.

“What I love about the Siemens solution is that you see the change instantly,” Chavez said. “You can address on-the-fly changes and eliminate the time-consuming back-and-forth that exists in traditional processes.”

The conversation between Steph Chavez and Erica Van Berkum underscored a clear reality: the future of electrical-electronic co-design depends on breaking down silos, adopting digital tools, and fostering a culture of adaptability.

As industries like automotive, aerospace, and electronics continued to evolve, organizations that embrace integrated, cross-functional design approaches will be best positioned for success. The future of electrical-electronic co-design lies in collaboration, automation, and adaptability.

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