Transmissions Structures Design/Release Engineer

Stellantis•Auburn Hills, MI

About The Position

The Gear Manufacturing Engineer develops, optimizes, implements, and supports manufacturing processes for gears used in automotive transmissions and related applications. The role covers gear production from raw material through final machining, including gear cutting, chamfering, heat treatment, shot peening, and finishing. It works cross-functionally with manufacturing, product engineering, design, quality, production, metrology, inspection teams, and suppliers to ensure manufacturability, specification compliance, product quality, and production readiness. The engineer supports prototype and serial-production activities, new product launches, process validation, and PPAP. The role also develops process documentation and quality controls, leads PFMEA and root-cause activities, specifies and procures manufacturing equipment and tooling, and improves process efficiency, cost, and quality. It includes gear tooling design and analysis, gear NVH end-of-line acceptability, and evaluation of new processes for feasibility and economic impact.

Requirements

Bachelor’s degree in Mechanical Engineering or a related degree field.
At least 5 years of experience.
Experience with gear manufacturing processes such as hobbing, shaping, skiving, grinding, honing, shot peening, and heat treatment.
Knowledge of gear design, GD&T, and quality standards such as AGMA, ISO, and DIN.
Proficiency with CAD/PLM tools such as NX, CATIA, and Teamcenter, and gear analysis software such as MASTA, LDP, and KissSoft.
Knowledge of different tooth measurement methods, including inline, offline, visual scan, and NVH.

Nice To Haves

Master’s degree in Engineering.
Experience in automotive or high-volume manufacturing environments.
Familiarity with advanced gear inspection techniques, including CMM and scanning.
Experience with process automation, advanced manufacturing processes, and continuous improvement initiatives.
Knowledge of Lean Manufacturing and Six Sigma principles.

Responsibilities

Develop and implement gear manufacturing processes from raw material to final machined gears, including gear cutting, chamfering, heat treatment, shot peening, and finishing.
Collaborate with manufacturing, product engineering, and design teams to ensure manufacturability and compliance with specifications.
Review product engineering gear prints.
Analyze and resolve manufacturing issues related to gear quality, dimensional accuracy, and surface finish.
Develop process documentation, work instructions, and training materials for new product launches, including process sheets and process flow charts.
Develop PFMEA documentation and lead PFMEA workshops.
Create control plans.
Support prototype-part production according to serial-production processes, including DFA and DFM, and perform tryouts, PPAP, and validation.
Lead root-cause analysis and corrective actions for gear-related manufacturing defects or failures.
Optimize manufacturing processes for efficiency, cost, and quality using Lean and Six Sigma methodologies.
Specify and procure gear manufacturing equipment, fixtures, and tooling.
Create technical documentation for sourcing, review supplier proposals, select suppliers, and perform equipment pre-acceptance at the selected supplier.
Define process parameters to meet serial-production quality requirements.
Lead gear NVH end-of-line acceptability, specifications, requirements, and first-time capability.
Design gear tooling, including hob cutters, broaches, and grinding and honing wheels.
Perform tool roll-out analysis, including analysis of process variations.
Work with metrology, inspection, and quality teams to ensure appropriate gear measurement and quality control; define drawing specifications and controls, including MSA, critical characteristics, and GD&T.
Stay current with developments in gear manufacturing, including machining, automation, and inspection.
Lead innovation projects to test the feasibility and economic impact of potential new processes.