Designer II

Federal Signal Openings • Fayette, AL

10d

About The Position

The Advanced Design Engineer drives the development of dump bodies, subframes, hoist systems, and related truck equipment with a strong focus on design for manufacturability, fixture‑based repeatability, and poka‑yoke integration. This role ensures that every product is engineered to build consistently on the shop floor without reliance on tape measures, operator judgment, or variable manual processes. The engineer leads structural design, manufacturability optimization, and continuous improvement efforts while collaborating with production, quality, sourcing, and sales to convert concepts into high‑performance, cost‑effective, mistake‑proof products.

Requirements

• Bachelor’s degree in Mechanical Engineering or related field.
• 3–7+ years of experience in metal fabrication, heavy equipment, truck bodies, or similar industries.
• Proficiency in 3D CAD and drafting.
• Strong understanding of structural steel design, weldments, and mechanical systems.
• Experience with FEA and engineering simulation tools.
• Ability to create engineering drawings with GD&T and clear manufacturing intent.

Nice To Haves

• Experience in dump body or vocational truck manufacturing.
• Familiarity with hydraulic circuits, hoist systems, and PTO‑driven equipment.
• Knowledge of lean manufacturing, DFM, and poka‑yoke design principles.
• Experience with ERP systems for BOM management.
• PE license or progress toward licensure.
• Strong mechanical aptitude and analytical thinking.
• Creativity with a focus on simplifying builds and eliminating variation.
• Excellent communication and project management skills.
• Detail‑oriented with strong problem‑solving abilities.
• Ability to lead cross‑functional projects.
• Commitment to safety, quality, and repeatable, measurement‑free manufacturing.

Responsibilities

• Product Design & Development Engineer dump bodies, tailgates, hoist structures, and subframes using 3D CAD with an emphasis on geometry that aligns with fixtures, hard stops, and standardized locating features.
• Create detailed drawings, weldments, and BOMs that support repeatable, fixture‑driven assembly rather than floor‑measured builds.
• Perform structural calculations and FEA to validate strength, fatigue life, and load paths.
• Lead new product development from concept through prototype, ensuring designs are optimized for manufacturability and error‑proof assembly.
• Design products that eliminate tape‑measure use by incorporating alignment tabs, slots, pins, datum surfaces, and modular subassemblies.
• Partner with production to convert measurement‑dependent tasks into poka‑yoke, fixture‑guided operations.
• Resolve manufacturing issues by redesigning components for simpler welding, forming, cutting, and assembly.
• Drive engineering change orders that reduce variation, shorten build time, and improve first‑pass yield.
• Develop test plans for prototypes with a focus on validating real‑world manufacturability, structural performance, and hydraulic integration.
• Analyze failures and implement corrective actions that strengthen both design robustness and production repeatability.
• Document results and feed lessons learned back into DFM standards and fixture design.
• Translate customer requirements into engineered solutions that can be built consistently across shifts and operators.
• Support purchasing in evaluating suppliers for steel, hydraulics, and hardware that meet manufacturability and quality standards.
• Work with quality teams to address field issues and implement design changes that prevent recurrence through poka‑yoke principles.
• Ensure all designs meet FMVSS, OSHA, SAE, ANSI, and industry standards while also aligning with internal DFM and error‑proofing guidelines.
• Maintain documentation consistent with ISO or other quality management systems.
• Lead weight‑reduction initiatives using engineered geometry that maintains strength while simplifying fabrication.
• Research new materials, coatings, hydraulic technologies, and fabrication methods that improve durability and manufacturability.
• Develop modular, fixture‑friendly designs that reduce lead times and support scalable production.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level