Expert Engineer - Interior Overhead Systems (DRE)
On-site · Troy, Michigan, United States
Job Summary
Lead end-to-end design release of Overhead Systems components (e.g., headliner, sun visor, grab handle, overhead console, interior lighting, microphones, cameras) across Client vehicle programs. Own and manage technical data (3D/2D CAD releases, GD&T drawings, PBOM/eBOM, piece numbers, and engineering documentation) through the full execution phase. Drive supplier engagement through APQP gates (design reviews, DFMEA, tooling feasibility, deliverable tracking, timing, cost/quality alignment). Build, own, and manage DVP&R plans; coordinate and validate test execution for durability, environmental, thermal, NVH, abuse, and safety requirements; track open items and drive closure with suppliers. Lead and participate in DFMEA development with suppliers; ensure DFMEA sign-off aligns with tooling release gates per APQP. Support prototype builds (Mule, VP, PPAP, Launch); attend in-plant build events as required. Manage tooling milestone gates (T1/T2/T3); coordinate tooling release sign-off, dimensional approval, CMM reviews, and PPAP/PSW submission. Apply root cause analysis tools (5-Why, KT, Red X) to diagnose and permanently resolve design, material, and manufacturing issues; lead corrective actions with suppliers. Manage engineering changes end-to-end (CNs/ECNs in Teamcenter); assess cost, weight, and timing impact; coordinate cross-functional approval. Define part breakup, assembly sequence, and master sections for the Program of Record (POR); develop source packages including PBOM, eBOM, tech sheets, and DVP&R. Perform packaging and feasibility studies for OHS components; evaluate DFM/DFMA compliance and drive design optimization with suppliers. Support decision-making using standard matrices; synthesize program requirements including financial targets, weight budgets, and complexity with styling. Maintain issue logbooks; present top open issues and risk status to management weekly; lead cross-functional actions to closure. Conduct benchmarking studies; identify cost reduction and value optimization opportunities. The role relies on a Bachelor’s degree and 8+ years of automotive interior/lighting product design, with expert CAD and PLM skills, DFMEA/APQP leadership, and strong cross-functional collaboration, in a Senior-level, full-time position based in Troy, MI. Compliance notices and equal opportunity statements are included.
Required Qualifications
- 8+ years of Product Design & Development experience in automotive Interior Trim and/or Lighting Components, with direct DRE execution-phase experience on Overhead Systems (Headliner, Sun Visor, Grab Handle, Overhead Console, Interior Lighting, Microphones, Cameras)
- Expert proficiency in CAD tools (CATIA V5/V6 or NX/UG) for 3D design release, 2D drawing creation, GD&T application, and master section development
- Expert-level proficiency in PLM/PDM systems (Teamcenter); full ownership of eBOM/PBOM structure, piece number management, and CN/ECN processing throughout execution phase
- Deep knowledge of DFM/DFMA principles and DFMEA development; proven ability to lead DFMEA sign-off with suppliers aligned to Client APQP gate requirements
- Demonstrated ownership of DVP&R plans: build, track, and close test execution for durability, environmental, thermal, NVH, abuse, and safety requirements; experience with PBOM/eBOM management and full technical documentation suite
- Ability to interpret feasibility criteria for styling and engineering integration; proficiency with formal root cause analysis tools (5-Why, KT, Red X) to drive permanent corrective actions
- Strong leadership in resolving complex cross-functional design issues; ability to mentor junior engineers and act as technical authority for OHS system on program
- Ability to manage full supplier lifecycle: technical reviews, APQP gate tracking, DFMEA, DVP&R coordination, tooling release, PPAP/PSW, and in-plant support for prototype builds and program launch
- Extensive knowledge of manufacturing and assembly feasibility, with demonstrated experience driving DFM optimization from concept through production ramp
- Desirable: Work experience with International Tier 1 and OEMs
- Language: Essential English
- Software: UG/NX & Teamcenter; MS Office or Google G-Suite
- Experience in full sourcing processes (In/Out/Explo, RFQ, supplier selection, SOR/SOW) and weight management - mass sign-off
Desired Qualifications
- Bachelor’s degree in Mechanical Engineering, Automotive Engineering, or related field
- 8+ years of Product Design & Development experience in automotive Interior Trim and/or Lighting Components
- expert proficiency in CAD tools (CATIA V5/V6 or NX/UG) for 3D design release, 2D drawing creation, GD&T, and master section development
- expert-level proficiency in PLM/PDM systems (Teamcenter); full ownership of eBOM/PBOM structure, piece number management, and CN/ECN processing
- deep knowledge of DFM/DFMA principles and DFMEA development; lead DFMEA sign-off with suppliers
- experience with APQP gates, DFMEA, DVP&R coordination, tooling release, PPAP/PSW, and in-plant support for prototype builds
- strong leadership and mentoring abilities; ability to manage supplier lifecycle and lead cross-functional teams
- ability to interpret feasibility criteria for styling and engineering integration; proficiency with root cause analysis tools (5-Why, KT, Red X)
- excellent communication and presentation skills; ability to lead design reviews and escalate risks to senior management
- experience with manufacturing and assembly feasibility, weight management, and mass sign-off processes
- in-depth knowledge of automotive interior component manufacturing processes (injection molding, compression molding, plastic welding, foaming, vacuum forming, thermoforming)
- experience with In/Out/Explo sourcing processes, RFQ packages, supplier selection, SOR/SOW development
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