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Product Design Development Engineer
2 months ago
Summary:
Become the product owner through Design, Development, and Validation of Stainless-Steel Bellows (dynamic couplings in gas/fluid systems) for the Light and Heavy Vehicle market segments. Work locally and globally in an innovative environment using both empirical and analytic methods to design, validate and verify product durability using customer and internal requirements. Conduct specialized testing at customer/OEM site, analyze data, and perform accelerated inhouse testing of design. Formulate reports and communicate results to technical and non-technical persons.
Product Development, Testing & Validation:
· Secure and maintain American Boa’s leading edge in engineering of Heavy Vehicle (Class 4 thru 8 trucks and off-highway) and Light Vehicle (Passenger car) stainless steel bellows including intake system, exhaust system, or on-engine locations.
· Plan, prepare, coordinate, and execute multiple consecutive vehicle measurements at OEM proving grounds, working with product development team and customer. Must coordinate and manage data acquisition progress correlating with customer durability schedules to ensure accurate and timely results.
- Utilize, innovate, and maintain state-of-the-art test and measurement equipment as well as fatigue test methods/techniques for road load data acquisition (RLDA) and validation.
· Design and implement custom measurement fixtures to use at customer site.
- Assure calibration and maintenance of all test and measurement equipment to establish accurate test result for essential product validation and decisions.
· Analyze measured data, make critical engineering decision to determine risk based on measured data
· Communicate and document clear, concise, and accurate test results to the customer and ABI engineering team. Maintain a close feedback loop with product design team based on results to drive design direction.
· Responsible for summarizing test results to be used as an input in engineering reports, including photos and additional observations that occurred during each test.
· Work with exhaust components and systems on vehicles for the purpose of benchmarking and/or R&D development vehicle testing and in-house data acquisitions.
· Strive for outstanding quality through process development and continuous improvement. Support the continuous improvement and development of state-of-the-art test and vehicle measurement methodologies through innovation and research.
- Innovate and support to continuously improve products for durability, function, manufacturability, and profitability.
- Create and take ownership of DVP&R and DFMEA documents for all new products.
- Occasional travel to customer sites to confidently represent American BOA in design reviews, technical presentations, and sales support as required.
Product Design:
- Lead and Collaborate cross functionally with Engineering, program management, quality, and manufacturing to lead NPD/NPI projects from conception through production launch, while using ABI’s Product Development Process.
- Identify opportunities for new and/or improvements to existing technologies, tools or processes
- Lead and collaborate with Tier 1 / OEM’s to determine necessity and/or feasibility of integrating a Flex Joint to satisfy internal and external DVP&R requirements including but not limited to corrosion, movement capabilities, full system response (low and high frequency), thermal boundary requirements, gas flow constraints, and fatigue life.
- Lead and participate in cross-functional design reviews for new (initial release) and change requests.
- Responsible for accurate bill of materials (BOM) for all initial releases and design changes (ECR).
- Utilization of SolidWorks to design flex joints.
- Experience with automated design (parametric/Design table) and its functionality within Enterprise PDM is a plus.
- Support APQP teams with prototype and development drawings for quotations and other new business opportunities using best engineering judgement and analysis through fatigue and motion theory.
- Create complete, accurate 2D drawing sets and BOMs with proper GD&T, tolerance stack-up, and compliance to global standards.
- Organize the exchange of 3d models and 2D drawing to/from customers and vendors to insure utilization of latest design revision. Ensure that 2D drawings and 3D CAD models requested by customer engineering comply with all requirements.
- Review, interpret, and react to customer data to drive product development progression.
- Prepare written documents such as standard operating procedures, memos, reports, and technical knowledge transfer documentation.
- Negotiate and mediate best GD&T solution internally with quality and manufacturing and/or externally with suppliers for functionality and economical manufacturability.
- Formulate engineering change request (ECR) into design proposals for discussion, distribution to the ECM committee members, and eventual release.
- Gatekeeper and local manager of EPDM database containing all CAD drawings.
Additional:
· Additional responsibility includes supporting test technicians in the test laboratory. This may include but not limited to the following: operation and setup of 6DOF testing, vibration shaker testing, A to B testing, corrosion testing, root cause failure analysis, benchmarking, and equipment maintenance and calibration.
Education and Experience:
· Required
- Four-year Bachelor of Science (BS) degree in Mechanical Engineering or engineering technology from an accredited college or university required
- High level of critical thinking in new and innovative areas.
- Ability to identify gaps in processes/products with the drive to absorb and drive innovation to completion.
o Must be self-motivated and self-lead, requiring little to no supervision and generate accurate results while working in a team environment.
o Innovation and technical leadership combined with exceptional sense for detail, accuracy and organization.
o Should be comfortable to confidently speak to large technically trained audiences (fellow engineers) and non-technically trained audiences alike.
o Sound engineering education and experience reflecting enthusiasm to design and develop state-of-the-art products utilizing CAD and CAE systems.
o Excellent communication skills in terms of collaborating with sales, manufacturing, domestic and third-party suppliers and customers.
o Ability to travel to customer locations within and outside of the USA to deliver technical presentations.
o Up to 25% of travel expected (includes domestic and international) [Case by case basis depending on current global situation]
· Preferred
o 2-3 years’ experience in SolidWorks – automated/parametric 3D and 2D drawing creation for manufacture preferred.
o Understanding of FMEA, DVP&R, PPAP, Design for Manufacturability, GD&T, tolerance stack analysis
o General knowledge of welding and metal forming processes.
o Working knowledge and understanding of metal fatigue, NVH concepts and vehicle powertrain a plus.
o Working knowledge of document control in Enterprise PDM and/or SAP is a plus.
o Working knowledge of statistical failure analysis, a plus.
o Experience in data acquisition and analysis techniques, equipment, and software.
o Experience with time based and frequency-based vibration phenomena.
Open Ended Questions:
· How is your previous experience relevant to this role? Why are you a good fit for this job?
· What about the role excites you and motivated you to apply? Please describe your interest in working with us.
· What interests you about this position.
· Share a time you had to use critical thinking to solve a problem.
· Tell me about a time when you came up with an innovative solution to a challenge your company/class/organization was facing. What was the challenge? What role did others play? What role did you play?
· What is the most difficult work-related decision you've ever had to make?
· Explain your decision-making process.
· Tell us about a new skill/ability you had to master as part of you last job. How did you learn the skill, and how did you verify your mastery?
Selection of level
· How many years of Designing Test Plans experience do you have?
· How many years of SolidWorks experience do you have?
· How many years of SolidWorks PDM experience do you have?
· How many years of Hands-On Mechanical experience do you have?
· How many years of OEM/Tier 1 experience do you have?
· How many years of NVH experience do you have?
· How many years of Failure Root Cause Analysis experience do you have?
· How many years of Welding and Metal Forming experience do you have?
· How many years of FHA BCP experience do you have?
· What is the highest level of education you have completed?
· When are you available for an interview or phone screen? Please list 2-3 dates and times or ranges of times.
