As a Sr. Dimensional Engineer, DFM/BiW, you will be involved in complete model launch phase – from product design development, manufacturing specification development, tooling & equipment development to line commissioning and SOP. The role requires deep understanding of Body product design, GD&T, and manufacturing processes. This role requires to develop the build plan of a product from the ground up based on manufacturing process feasibility and best dimensional quality. Role will also require hands on involvement for product assembly & tooling measurements, troubleshooting and certification. This role requires to work in cross functional team environment with a strong influential ability to drive product design build based on best manufacturing practices for body accuracy.
You Will:
- Develop / architect body build sequence based on manufacturing process size scope, body dimensional accuracy, process variation
- Develop / architect body assembly datum strategy based on efficient & flexible assembly tooling design and body dimensional accuracy control
- Lead Product DFM, Simultaneous Engineering activities and support NPI – design feasibility, dimensional & body accuracy feasibility, body sequencing, tooling design
- Work with Product Engineering for DFM related product design changes
- Develop Manufacturing based variation analysis models and align with product design variation analysis to meet design requirements based on manufacturing reality
- Align body equipment PLP and part / assembly level GD&Ts and develop Body dimensional control points to ensure closed loop dimensional traceability
- Lead & Manage Prototype builds and New Model Launch Body Dimensional accuracy plan
- Analyze, troubleshoot and develop control plan to meet body dimensional metrics and contain variation
- Coordinate with Metrology to manage measurement, inspection and verification work flow for prototype and product launch / commissioning builds
- Hands on involvement – participate and buy-off on Fixture/tooling part fitting, fixture certification, product assembly measurements and certification
- Lead dimensional build activities during tooling try outs at launch to achieve stable, repeatable and in dimensional spec body prior to SOP
- Coordinate with Supply Chain, Supplier Quality, Stamping & NPI team for feedback loop for stampings, extrusions, castings, etc.
- Collaborate with product and manufacturing engineering on new manufacturing process research and development
- Participate in new manufacturing process specification development, assembly tooling design reviews and buy-offs
- Develop assembly fixture, ACP / PCF fixture specifications and manage procurement for model launch programs
- Work with Quality Engineering team to problem solve and improve overall product quality with dimensional body accuracy focus
- Support stamping gage / check fixtures Buy-off
- Support PPAP process as needed from supplier parts
- Develop Facility Specifications & Bid Documentation and participate in facility (building) and process equipment RFQ process
- Assist Manufacturing Engineering & NPI team in coordinating & tracking Product Release and engineering changes
- Knowledge of latest innovations in manufacturing engineering and applications
- Maintain strong relationships with other company groups (Product Design, Production Engineering, Studio Engineering, Metrology, Supply Chain, Supplier Quality, etc) to progress BIW Manufacturing objectives
You Bring:
- Bachelors in Mechanical Engineering or related Field required
- 5+ years of professional experience required
- Strong Interposal Skills with ability to Coordinate cross functional teams and deliver target initiatives
- Expert in GD&T
- Experience in Dimensional Variation Analysis (3D and 2D Stack up)
- Experience in using Polyworks software
- Experience in Aluminum and Steel Body Structures
- Experience with Measurement Systems, Metrology equipment (ie. Faro Arms, Light Scanners, etc.)
- Knowledge of Production & Quality Control in manufacturing
- Extensive Experience in BIW Product development and Manufacturing Processes
- Software: 3DCS, AutoCAD, Catia (3DExperience) and MS Office
- Six Sigma Green Belt &/or proven Experience with Statistical Process Control
- Strong communication and presentation skills
- Independent and Strong sense of personal responsibility and accountability for delivering high quality work
- Analytical and problem-solving skills
- 40% Domestic and International Travel Required
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