Design Release Engineer (DRE) – Overhead Systems

ALTEN Technology USA•Auburn Hills, MI

11h

About The Position

ALTEN Technology USA is seeking a Design Release Engineer to lead end-to-end design release for Overhead Systems (OHS) components—including headliners, sun visors, grab handles, overhead consoles, interior lighting, microphones, and cameras—across client vehicle programs. The role owns component technical data and engineering documentation throughout program execution, manages suppliers and APQP deliverables, and coordinates design, validation, tooling, and production-readiness activities. The engineer develops and manages DVP&R plans and coordinates testing, leads supplier DFMEA and corrective-action work, supports prototype builds and in-plant events, and manages tooling milestones through dimensional approval and PPAP/PSW submission. The role also manages engineering changes in Teamcenter, develops program source packages and component structures, evaluates packaging and manufacturing feasibility, supports sourcing decisions, identifies cost and value opportunities, and communicates program risks and open issues to management. The position requires extensive automotive product design and development experience, particularly direct execution-phase work on overhead systems. It calls for expert CAD and PLM/PDM capability, knowledge of automotive interior manufacturing processes and APQP, and the ability to lead suppliers and cross-functional teams from design through production ramp. A bachelor's degree in Mechanical Engineering, Automotive Engineering, or a related field is preferred. English is essential; knowledge of UG/NX, Teamcenter, and MS Office or Google G-Suite is specified.

Requirements

8+ years of product design and development experience in automotive interior trim and/or lighting components, including direct DRE execution-phase experience with Overhead Systems.
Expert proficiency with CATIA V5/V6 or NX/UG for 3D design release, 2D drawing creation, GD&T application, and master section development.
Expert-level proficiency with PLM/PDM systems, particularly Teamcenter, including eBOM/PBOM structure ownership, piece number management, and CN/ECN processing.
Deep knowledge of DFM/DFMA principles and DFMEA development, with demonstrated ability to lead supplier DFMEA sign-off aligned to client APQP gates.
In-depth knowledge of automotive interior component manufacturing processes, including injection molding, compression molding, plastic welding, foaming, vacuum forming, and thermoforming.
Experience managing T1/T2/T3 tooling milestones, dimensional approval, and CMM reviews through PPAP/PSW.
Demonstrated ownership of DVP&R plans, including building, tracking, and closing tests for durability, environmental, thermal, NVH, abuse, and safety requirements.
Ability to interpret styling and engineering integration feasibility criteria and use formal root-cause tools such as 5-Why, KT, and Red X.
Proven ability to lead resolution of complex cross-functional design issues and act as a technical authority; mentoring junior engineers is expected.
Strong communication and presentation skills, including leading design reviews and escalating risks to senior management.
Ability to manage the full supplier lifecycle, including technical reviews, APQP tracking, DFMEA, DVP&R coordination, tooling release, PPAP/PSW, and in-plant prototype and launch support.
Expert-level knowledge of manufacturing and assembly feasibility, with experience driving DFM optimization from concept through production ramp.
English language proficiency is essential.
Knowledge of UG/NX and Teamcenter.
Knowledge of MS Office or Google G-Suite.

Nice To Haves

Bachelor’s degree in Mechanical Engineering, Automotive Engineering, or a related field (preferred education).
Work experience with international Tier 1 suppliers and OEMs.
Extensive in-plant experience with T1/T2/T3 tool tryouts, prototype builds (Mule, VP, PPAP, Launch), assembly line support, and program launch activities at supplier and OEM facilities.
Familiarity with client-specific processes and milestones, including SOP readiness reviews, client APQP phases and gates, eVIEW/ePDM, and Teamcenter authoring.
Experience in the full sourcing process, including In/Out/Explo, RFQ packages, supplier selection, and SOR/SOW development.
Knowledge of weight management and mass sign-off processes.

Responsibilities

Lead end-to-end design release of Overhead Systems components across client vehicle programs.
Own and manage technical data, including 3D/2D CAD releases, GD&T drawings, PBOM/eBOM, piece numbers, and engineering documentation through execution.
Drive supplier engagement through APQP gates, including design reviews, DFMEA, tooling feasibility, deliverable tracking, timing, cost, and quality alignment.
Build and manage DVP&R plans; coordinate and validate durability, environmental, thermal, NVH, abuse, and safety testing, track open items, and drive closure.
Lead and participate in supplier DFMEA development and ensure sign-off aligns with tooling release gates and client APQP requirements.
Support prototype builds—including Mule, VP, PPAP, and Launch—to resolve fit, finish, function, and integration issues; attend supplier and assembly facility build events as required.
Manage T1/T2/T3 tooling milestones, tooling release sign-off, dimensional approval, CMM reviews, and PPAP/PSW submission.
Use 5-Why, KT, and Red X root-cause analysis tools to resolve design, material, and manufacturing issues and lead supplier corrective actions.
Manage engineering changes end-to-end in Teamcenter, assessing cost, weight, and timing impacts and coordinating cross-functional approval.
Define part breakup, assembly sequence, and master sections for the Program of Record; develop source packages including PBOM, eBOM, tech sheets, and DVP&R.
Perform packaging, manufacturing, and assembly feasibility studies for OHS components; evaluate DFM/DFMA compliance and drive design optimization with suppliers.
Support In/Out/Explo decisions using decision matrices for quality, cost, timing, and performance; synthesize program requirements, financial targets, weight budgets, and styling complexity.
Maintain issue logbooks, present top open issues and risks to management weekly, and lead cross-functional actions to closure.
Conduct benchmarking and identify cost-reduction and value-optimization opportunities throughout the program lifecycle.
Lead design reviews, escalate risks, and align cross-functional stakeholders including Styling, Safety, Manufacturing, Purchasing, and Quality.
Mentor junior engineers and act as the technical authority for OHS systems on the program.