Exterior Lighting Product EngineerOverview / Summary The Exterior Lighting Product Engineer is a multidisciplinary technical role responsible for the design, development, integration, validation, and technical integrity of automotive exterior lighting systems. This position works across mechanical, electrical, software, and optical engineering disciplines and supports the development of exterior lighting components including headlamps, taillamps, center high-mounted stop lamps (CHMSL), fog lamps, license plate lamps, and other lighting systems.
The role involves CAD development, optical engineering, injection molding, laboratory diagnosis, design release activities, technical analysis, validation, and cross-functional collaboration to deliver robust and manufacturable lighting systems.
Key Responsibilities - Support the design, development, integration, and validation of automotive exterior lighting systems and components.
- Perform hands-on laboratory diagnosis and root-cause analysis of lighting issues, including warranty-related issues.
- Use laboratory equipment such as microscopes, multimeters, hand tools, and light power tools to inspect and test lighting components and electronics.
- Utilize CAD software such as CATIA V5 to develop lighting CAD, including concepts, fixtures, and small lamps.
- Design optical systems for small lighting applications.
- Apply injection molding and design-for-manufacturing knowledge when developing 3D CAD.
- Support the design and development of injection molds.
- Manage design and release activities to deliver and validate parts according to program timelines.
- Support part number generation, cost analysis, weight analysis, feasibility studies, and cross-functional coordination.
- Collaborate with cross-functional teams to evaluate and validate lighting component system interfaces at the vehicle level.
- Perform and/or review technical analyses and functional and packaging studies, including dimensional stack-ups, GD&T layouts, CAE analyses, dynamic calculations, and simulations.
- Review and sign off CAD in Teamcenter.
- Develop lighting system documents, including DFMEAs, SCCAFs, Boundary Diagrams, P-Diagrams, and DVP&Rs.
- Lead design reviews based on Failure Mode Avoidance.
- Develop Engineering Statements of Work (ESOW) and Engineering Concepts (EC).
- Participate in sourcing activities, including piece-cost and tooling-cost reviews.
- Identify required validation, durability, and functional testing.
- Address technical issues through root-cause analysis, including 8D and 3x5 Why methodologies, and implement permanent corrective actions.
- Apply Six Sigma principles to engineering and problem-solving activities.
- Collaborate with supplier technical teams and support supplier engagement activities.
- Create and present technical presentations for peer and management reviews.
- Actively participate in Technical Design Reviews.
- Manage multiple technical issues effectively and prioritize workload.
- Travel to supplier manufacturing and testing sites and manufacturing plants in North America when required.
- Work effectively in a fluid environment where vehicle targets, size, appearance, and manufacturing location may not always be fully defined.
- Adapt to a variety of applications and technical issues as required.
Required Qualifications - Bachelor's degree or higher in Mechanical Engineering or a related field.
- 5+ years of experience in the design, development, or launch of automotive lighting or similar components.
- Experience with CAD tools such as CATIA, 3DX, and Teamcenter.
- Familiarity with CAE tools and software.
- Experience with benchmarking.
- Experience integrating and developing CAD studies to support design improvements.
- Experience with laboratory diagnosis, product development, electrical engineering, 3D modeling, optical engineering, and injection molding.
- Ability to account for manufacturability when developing 3D CAD.
- Ability to support design and release activities and deliver and validate parts according to program timelines.
- Ability to perform root-cause analysis and problem solving.
- Ability to manage multiple issues effectively and efficiently.
- Demonstrated initiative and ability to prioritize workload.
- Ability to travel domestically and internationally.
- Proficiency with Microsoft Office applications, including Excel, Word, PowerPoint, Microsoft Teams, and Microsoft Azure SharePoint.
Preferred Qualifications - Master's degree in Engineering, preferably Mechanical Engineering.
- 7+ years of experience.
- Experience in the design and release of exterior lighting.
- Software literacy and mechatronics experience.
- Strong understanding of statistical analysis.
- Experience with 8D and 5 Why corrective action and problem-solving methods.
- Experience with DFMEAs, PFMEAs, and SCCAFs.
- Detailed understanding of materials, manufacturing technologies, and GD&T.
- Ability to solve complex system issues involving a variety of variables where limited standardization exists.
- Effective oral and written communication skills.
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