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Position Overview The Senior Engineer, Suspension Structures provides technical leadership and hands-on engineering support for suspension structural systems throughout vehicle launch, production ramp-up, and series manufacturing. This role serves as the primary plant engineering focal point for knuckles, control arms, subframes, links, bushings, wheel carriers, and related structural chassis components.
The engineer works closely with Design Engineering, CAE, Manufacturing Engineering, Quality, Supplier Quality, Purchasing, and Plant Operations to ensure vehicle quality, safety, durability, NVH performance, and manufacturing efficiency. The role is critical for rapid production issue resolution, vehicle launch support, and continuous improvement. Responsible for sustaining engineering after initial product launch.
This includes design and release of new parts as required such as to improve quality or the assembly process. Working with core engineering to ensure parts meet all design and validation requirements. Key Responsibilities Production Support & Issue Resolution • Serve as the plant technical expert for front/rear knuckles, upper/lower control arms, suspension links, front/rear subframes, crossmembers, structural brackets and mounts, bushings, and compliant joints.
• Investigate and resolve vehicle build, fit-up, dimensional, durability, corrosion, and quality concerns. • Lead root cause analysis for manufacturing, supplier, and field issues. • Implement containment actions and drive permanent corrective actions. • Support daily production meetings and manufacturing escalations; minimize downtime related to chassis structural component issues. Launch & Program Support • Support prototype, DV, PV, and production vehicle builds.
• Coordinate engineering change releases and plant implementation plans. • Track launch issues and ensure timely closure. • Support vehicle build events and launch reviews. Dimensional & Manufacturing Engineering • Support dimensional variation analysis and build quality improvement activities. • Investigate stack-up, tolerance, and alignment issues. • Collaborate with manufacturing teams to improve assembly robustness.
• Support implementation of poka-yoke and process improvements. • Reduce rework and scrap associated with chassis structures. Structural Performance, Supplier Quality & Continuous Improvement • Support validation sign-off activities and production readiness reviews. • Interface directly with suspension structure suppliers and lead technical reviews for quality, production, dimensional, and durability concerns.
• Support supplier containment and corrective action implementation. • Participate in supplier audits and launch readiness reviews. • Drive continuous improvement initiatives with suppliers and internal cross-functional teams. • Develop predictive quality