Air Induction Design and Release Engineer

Stellantis•Auburn Hills, MI

About The Position

The Design Release Engineer for the Engine Air Handling Systems is responsible for the design, development, and technical leadership in the creation, validation, and release of Air Handling hardware and systems including INTAKE MANIFOLDS, cold air ducts, etc. This includes all components associated with getting air into and out of the engine including boosting hardware, charge air cooling, purge systems, etc. The role involves driving the design through all phases of the product lifecycle, including design concept, engineering validation, and production release through PPAP (Production Part Approval Process).

Requirements

A minimum of a Bachelor of Science degree in Mechanical or Aeronautical Engineering or related degree field.
A minimum of 5 years of relevant experience working with design and manufacturing of turbocharger components, including metal stamping and casting.
Understanding of engine components related manufacturing processes, i.e. Aluminum/steel stamping, aluminum casting, machining, etc…
Understanding of product development documentation such as, DFMEA and DVP&R.
Understanding of Mechanics of Materials, Sealing systems, CAE Analysis, and GD&T.
Experience in selecting materials and manufacturing methods for mechanical components.
Ability to author system/component level requirements.
Strong interpersonal communication, team/leadership skills/experience.
Strong oral and written communication skills.
Strong project management skills/experience.
Demonstrated understanding of structural analysis and failure modes of complex mechanical systems.

Nice To Haves

Advanced degree in Mechanical or Aeronautical Engineering.
Working experience in creation and execution of validation plans.
Critical character traits to ensure success: Action Oriented, Dealing with Ambiguity, Customer Focus, Problem Solving.
Working experience with 3D cad programs, preferably Siemens NX.

Responsibilities

Lead the design of the Engine Air Handling System hardware, ducting and engine interfaces.
Develop and refine the Air Handling and Purge System for function, cost and quality, durability, NVH, etc.
Support CAD modeling, FEA (Finite Element Analysis), and other design validation methods to ensure structural integrity and compliance with standards.
Collaborate with other engineering teams (airflow, thermal, packaging) to integrate the turbocharger system.
Manage design release activities from early concept through production, including the timely completion of B-Sample, C-Sample, X0, X1, X2, and X3 milestones.
Own the Bill of Materials (BOM) and Engineering Change Notices (ECNs) for turbocharger components.
Ensure all parts meet quality, cost, and timing requirements.
Drive the Production Part Approval Process (PPAP) for turbocharger components, ensuring compliance with all regulatory and customer specifications.
Coordinate with cross-functional teams, including manufacturing, suppliers, and quality, to ensure the successful release and implementation of designs.
Provide technical leadership and support during the development and production stages to resolve design issues, material selection challenges, and process-related problems.
Lead DFMEA (Design Failure Mode and Effects Analysis) and other risk assessment activities to ensure design robustness and mitigate potential issues.
Participate in the development of testing strategies for turbocharger components, including vibration, crash, and thermal testing.
Work closely with suppliers to ensure design feasibility, cost competitiveness, and manufacturability of turbocharger components.
Collaborate with validation teams to define and implement validation testing, ensuring turbocharger components meet functional and performance metrics.
Partner with vehicle integration teams to ensure proper fitment, safety, and integration of turbocharger components into the overall vehicle platform.
Develop and maintain engineering documentation, including design specifications, drawings, test plans, and validation reports.
Ensure that all technical documentation is up-to-date and aligns with program timelines and PPAP requirements.
Report on project status, timelines, and risk assessments to senior management and stakeholders.