Design Systems Application Engineer

Bot Verification•Auburn Hills, MI

About The Position

The Design Systems Engineer serves as the primary technical integrator and systems owner for axle, driveline, transfer case, gear reducer, and 4WD systems throughout the product development lifecycle. The role is the key interface among the Chief Engineer organization, Product Release Center (PRC), Development Validation Center (DVC), manufacturing, suppliers, and component engineering teams, ensuring vehicle, subsystem, software, manufacturing, and supplier interfaces work together as a cohesive system. The position drives system architecture, interface management, vehicle integration, manufacturability, technical risk mitigation, validation planning, change management, prototype build readiness, quality initiatives, and cost optimization from concept through production launch and continuous improvement. It owns system-level definition and integration; translates vehicle-level requirements into subsystem and component requirements; and leads reviews to achieve performance, durability, manufacturability, NVH, serviceability, and quality objectives. The role manages critical system interfaces and packaging, coordinates virtual development and validation, leads technical risk and quality activities, and supports engineering change governance and release readiness. It also leads cost-reduction and value-optimization efforts, supports program planning and business cases, and facilitates technical alignment across engineering, manufacturing, suppliers, purchasing, and validation organizations.

Requirements

Expertise in beam axle systems, independent axle systems, driveline systems, transfer cases, prop shafts, chassis systems, suspension systems, steering systems, brake systems, vehicle dynamics fundamentals, and 4WD/AWD systems.
Knowledge of CAD and digital mockup reviews, FC/CAD integration, virtual development processes, engineering change management, BOM management, interface control documentation, design freeze processes, validation planning and execution, nCode analysis, duty-cycle development, data acquisition and synthesis, program launch readiness, and GIMS and quality management processes.
System-level thinking and capability in architecture development and decision-making, complex problem solving, cross-functional integration leadership, technical trade-off analysis, and risk identification and mitigation.
Ability to challenge technical assumptions constructively, facilitate engineering consensus, lead technical reviews and decision forums, translate vehicle-level requirements into actionable engineering deliverables, and align suppliers and stakeholders.
Strong ownership mindset, high attention to technical detail, ability to manage multiple complex technical issues simultaneously, proactive issue identification and escalation, commitment to program timing, deliverables, and quality objectives, and ability to lead teams through ambiguity and drive closure of critical actions.

Responsibilities

Own system-level definition, integration, and balancing of front and rear axle systems, drivelines and prop shafts, transfer cases, gear reducers, 4WD functional software, vehicle interfaces, and supporting subsystems.
Ensure technical alignment across axles, suspension, steering, brakes, frame and chassis systems, powertrain interfaces, calibration teams, manufacturing organizations, suppliers, and validation organizations.
Translate vehicle-level requirements into subsystem- and component-level design requirements and maintain consistent engineering assumptions, requirements, interface definitions, and design intent.
Lead system integration reviews and technical assessments to meet vehicle performance, durability, manufacturability, NVH, serviceability, and quality objectives.
Own critical system interfaces, including transmission-to-driveline, axle-to-frame, driveshaft and transfer case, suspension attachment, chassis, vehicle hardpoints, and surrounding systems.
Define and control interfaces; validate packaging and functional clearances; assess tolerance stack-ups, manufacturing compatibility, assembly feasibility, serviceability, design release recommendations, duty cycles, and damage and failure modes.
Lead vehicle packaging reviews, identify interface conflicts early, assess impacts of component movement, geometry changes, and architecture decisions, and drive resolution of integration concerns across organizations.
Schedule and lead cross-functional design reviews across PRC and supporting engineering organizations; coordinate virtual analysis activities and CAE reviews.
Ensure Virtual DVP and Engineering Scorecards are completed before prototype hardware releases; lead FC/CAD integration and digital mockup reviews; and coordinate digital validation of component and subsystem interfaces.
Support engineering release readiness through design assessments and model reviews, and develop and maintain system-level requirements in virtual development environments.
Review validation status with DVC and provide periodic readiness assessments to Chief Engineering leadership; ensure validation plans, design verification activities, and technical signoffs support robust product development.
Identify architecture, integration, packaging, structural, manufacturing, and validation risks; lead root-cause investigations and technical problem-solving; establish mitigation plans and drive technical closure.
Coordinate DFMEA and DRBFM activities, establish and maintain design controls and development actions, lead cross-functional quality and issue-resolution task forces, manage GIMS investigations and issue tracking, and coordinate DRBTR reviews and follow-up actions.
Recommend escalation paths and resource requirements to support program success.
Review and approve engineering change notices and design modifications; update and incorporate lessons learned, engineering checklists, technical standards, and best practices into future designs.
Represent the Chief Engineer in program lessons-learned activities and collaborate with Technical Specialists and Centers of Excellence to improve technical standards and design practices.
Manage engineering complexity and assembly part-number strategies; maintain BOM structures and complexity charts for axle, driveline, transfer case, and gear reducer systems; coordinate engineering release readiness and design freezes.
Lead Technical Cost Reduction (TCR) and Value Optimization initiatives and work with PRC, DVC, suppliers, purchasing, and value-optimization teams to identify cost-saving opportunities.
Support Chief Engineering leadership with resource planning, client forecasting, engineering budgets, ER&D / ED&D cost rollups, and new-program planning; support business-case development and program execution strategies.
Serve as the primary systems engineering interface among Chief Engineering, PRC, manufacturing, suppliers, validation organizations, and vehicle engineering teams.
Facilitate technical consensus and decision-making, constructively challenge design assumptions, lead supplier technical reviews and integration discussions, and drive stakeholder accountability and alignment.
Work on special projects and strategic initiatives as assigned.