Design Systems Application Engineer

Job Description

Job Description

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. Acting as the key interface between the Chief Engineer organization, Product Release Center (PRC), Development Validation Center (DVC), manufacturing, suppliers, and component engineering teams, this role ensures all vehicle, subsystem, software, manufacturing, and supplier interfaces function as a cohesive and optimized system.

The position is responsible for driving 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.

Primary Responsibilities

Systems Architecture & Product Integration

" Own system-level definition, integration, and balancing of:

o Front and rear axle systems

o Drivelines and prop shafts

o Transfer cases

o Gear reducers

o 4WD functional software

o Vehicle interfaces and supporting subsystems

" Ensure technical alignment and integration across:

o Axles

o Suspension systems

o Steering systems

o Brake systems

o Frame and chassis systems

o Powertrain interfaces

o Calibration teams

o Manufacturing organizations

o Suppliers

o Validation organizations

" Translate vehicle-level requirements into subsystem and component-level design requirements.

" Maintain consistency of engineering assumptions, requirements, interface definitions, and design intent across all supporting organizations.

" Lead system integration reviews and technical assessments to ensure robust vehicle performance, durability, manufacturability, NVH, serviceability, and quality objectives are achieved.

Interface Management & Packaging Leadership

Serve as the technical owner for all critical system interfaces, including but not limited to:

" Transmission-to-driveline interfaces

" Axle-to-frame interfaces

" Driveshaft and transfer case interfaces

" Suspension attachment points

" Chassis systems

" Vehicle hardpoints and surrounding systems

Responsibilities include:

" Interface definition and control

" Packaging validation

" Functional clearance verification

" Tolerance stack-up assessment

" Manufacturing compatibility reviews

" Assembly feasibility assessments

" Serviceability evaluations

" Design release recommendations

" Duty cycle definition and verification

" Damage and failure mode analysis

" Lead vehicle packaging reviews and identify interface conflicts early in the development process.

" Evaluate impacts of component movement, geometry changes, and architecture decisions on surrounding vehicle systems.

" Drive technical resolution of integration, packaging, and interface concerns across multiple organizations.

Virtual Development & Systems Validation

" 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 prior to prototype hardware releases.

" Lead FC/CAD integration activities and digital mockup reviews.

" Coordinate digital validation of component and subsystem interfaces.

" Support engineering release readiness through design assessments and model reviews.

" Develop and maintain system-level requirements within virtual development environments.

" Review system validation status with the Development Validation Center and provide periodic readiness assessments to Chief Engineering leadership.

" Ensure validation plans, design verification activities, and technical signoffs support robust product development.

Technical Risk Management & Quality Leadership

" Identify system architecture, integration, packaging, structural, manufacturing, and validation risks.

" Lead root cause investigations and technical problem-solving activities.

" Establish mitigation plans and drive technical closure of issues.

" Coordinate Design Failure Mode and Effects Analysis (DFMEA) and Design Review Based on Failure Mode (DRBFM) activities.

" Ensure robust design controls and development actions are established and maintained.

" Lead cross-functional quality and issue-resolution task forces.

" Manage GIMS investigations and technical issue tracking.

" Coordinate DRBTR reviews and maintain accountability for open actions and follow-up items.

" Recommend escalation paths and resource requirements to ensure program success.

Product Development, Change Management & Governance

" Review and approve engineering change notices and design modifications.

" Ensure lessons learned, engineering checklists, technical standards, and engineering best practices are updated and incorporated into future designs.

" Act as the Chief Engineer's representative for program lessons learned activities.

" Collaborate with Technical Specialists and Centers of Excellence to continuously 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 freeze activities.

Cost Optimization & Program Support

" Lead Technical Cost Reduction (TCR) and Value Optimization initiatives.

" Work closely with PRC, DVC, suppliers, purchasing, and value optimization teams to identify cost-saving opportunities.

" Support Chief Engineering leadership with:

o Resource planning

o Client forecasting

o Engineering budgets

o ER&D / ED&D cost rollups

o New program planning

" Support business case development and program execution strategies.

Cross-Functional Leadership & Supplier Management

" Serve as the primary systems engineering interface between:

o Chief Engineering, Product Release Center, Manufacturing, Suppliers, Validation organizations, Vehicle engineering teams

" Facilitate technical consensus and decision-making across organizations.

" Challenge design assumptions where necessary to ensure optimal technical outcomes.

" Lead supplier technical reviews and integration discussions.

" Drive accountability, execution, and alignment across all stakeholders.

" Work on special projects and strategic initiatives as assigned.

Required Technical Expertise

Vehicle Systems

" Beam axle systems

" Independent axle systems

" Driveline systems

" Transfer cases

" Prop shafts

" Chassis systems

" Suspension systems

" Steering systems

" Brake systems

" Vehicle dynamics fundamentals

" 4WD/AWD systems

Product Development Tools & Processes

" 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

" GIMS and Quality Management Processes

Critical Competencies

Technical Leadership

" System-level thinking

" Architecture development and decision making

" Complex problem solving

" Cross-functional integration leadership

" Technical trade-off analysis

" Risk identification and mitigation

Influence & Communication

" Ability to challenge technical assumptions constructively

" Facilitate engineering consensus

" Lead technical reviews and decision forums

" Translate vehicle-level requirements into actionable engineering deliverables

" Drive supplier and stakeholder alignment

Execution & Accountability

" 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

" Ability to lead teams through ambiguity and drive closure of critical actions