Senior Engineer, Chassis Systems

About the Role
The Senior Engineer, Chassis Systems is responsible for ensuring chassis manufacturing quality by executing and continuously improving chassis system assembly, wheel alignment processes, torque-controlled joint assembly, wheel and tire installation, and end-of-line vehicle validation. This role acts as the primary technical interface between Vehicle Engineering, Manufacturing, Quality, Controls, Supplier Quality, Service Engineering, and Plant Operations to guarantee that all vehicles meet alignment, handling, safety, and customer satisfaction targets prior to shipment. The position involves sustaining engineering after the initial product launch, including the design and release of new parts destined to improve quality or the assembly process while ensuring compliance with all design and validation requirements.

Key Responsibilities

Chassis System Assembly Ownership

• Serve as plant technical lead for chassis assembly operations including front and rear suspension modules, steering system installation, brake system installation, wheels and tires, subframe marriage processes, spring/damper/air suspension assembly, and steering gear/tie rod/knuckle assembly.
• Ensure chassis assembly processes achieve safety, quality, throughput, and cost objectives.
• Partner with Manufacturing Engineering to develop and optimize assembly sequences, tooling, ergonomics, and workstation layouts.
• Support assembly process validation during prototype, pilot, and production builds.
• Investigate and resolve assembly-related concerns including part fit-up issues, excessive installation force, dimensional variation, and fastener accessibility concerns.
• Lead root cause analysis of manufacturing defects resulting from chassis assembly processes.

Joint Tightening & Fastening Integrity

• Own resolution of production issues related to chassis joint integrity and torque-controlled assembly processes.
• Support tightening strategy, torque traceability, tool capability, process controls, and fastener accessibility improvements.
• Partner with Manufacturing Engineering, Controls, and Quality to enhance joint quality and minimize rework.

Wheel Alignment & Vehicle Geometry

• Serve as plant technical lead for front and rear wheel alignment, camber, caster, toe, thrust angle, ride height settings, ClearVision performance, pull/drift performance, and steering wheel centering.
• Support optimization of automated wheel alignment stations, alignment equipment, and plant tooling.
• Establish robust alignment specifications and process controls.
• Investigate alignment-related customer concerns and warranty claims.
• Drive reduction in wheel alignment variability across production.
• Support development and improvement of alignment stations, ride-height measurement systems, steering angle verification, pull/drift audits, and ClearVision audits.
• Lead troubleshooting of end-of-line equipment and process failures.

Wheels, Tires & End-of-Line Quality Validation

• Serve as technical owner for wheel assemblies, tire fitment, wheel balancing, tire pressure process controls, and assembly variation management.
• Support end-of-line vehicle validation activities for chassis-related performance, geometry, handling, and customer satisfaction targets.
• Assist with production launch readiness, issue tracking, corrective actions, and continuous improvement activities.

Sustaining Engineering

• Design and develop automotive chassis components and assemblies to deliver the highest level of performance in NVH, Durability, and Manufacturability while optimizing cost.
• Collaborate closely with stakeholders and attribute owners across the company including Core Engineering, Vehicle Safety, Vehicle Dynamics, NVH, Durability, Manufacturing, Design Studio, etc.
• Work cross-functionally with Manufacturing, Design, and Product Development, as well as with Purchasing, Supplier Quality, and Suppliers on items such as tool buy-offs and secondary component changes.

Skills

• Deep understanding of wheel alignment theory, tire behavior, steering systems, chassis fastening systems, vehicle handling fundamentals, and chassis system assembly processes.
• Working knowledge of wheel alignment, chassis integration, manufacturing engineering, quality engineering, and vehicle launch support.
• Hands-on knowledge of GD&T, root cause analysis, DFMEA, PFMEA, statistical process control, and production issue resolution.
• Experience or familiarity with Duerr alignment equipment, Atlas Copco tightening systems, torque traceability systems, and Minitab.
• Knowledge of vehicle pull, drift, ClearVision, and steering performance assessments.
• Strong technical ownership, data-driven decision making, continuous improvement mindset, and manufacturing/field-quality orientation.
• Excellent communication skills across Vehicle Engineering, Manufacturing, Quality, Controls, Supplier Quality, Service Engineering, and Plant Operations.
• Six Sigma Black Belt, Green Belt, Shannin RedX or other equivalent problem-solving methodology.
• Experience in full life cycle development from concept to prototype to full production.
• Ability to create testing plans and conduct/coordinate physical tests to validate design concepts and ensure performance targets are achieved.
• Proficient in reading and interpreting GD&T.
• Hands-on practical experience in prototype assembly and production assembly, with a willingness to assemble parts independently.
• Capable of deriving clamp load and torque values for critical joints.

Minimum Qualifications

• Bachelor's degree in Mechanical Engineering, Automotive Engineering, Manufacturing Engineering, or a related field.
• 5+ years of automotive engineering experience.
• Experience in one or more of the following areas: vehicle dynamics, wheel alignment, manufacturing engineering, chassis integration, quality engineering, or vehicle launch support.
• Strong knowledge of wheel alignment theory, tire behavior, steering systems, chassis fastening systems, vehicle handling fundamentals, GD&T, root cause analysis, DFMEA/PFMEA, and statistical process control.
• Strong hands-on troubleshooting skills.
• Experience with a 3D CAD system such as CATIA or similar software.
• Design release engineering experience including engineering change management and project management experiences.

Compensation & Benefits
A comprehensive and competitive benefits package is offered, including medical, dental, and vision insurance; life and disability coverage; paid time off; paid holidays; paid sick leave; and a 401(k) retirement plan. Hourly/non-exempt employees accrue up to 120 hours of paid time off, while salaried/exempt employees accrue up to 160 hours. Eligible employees may also participate in an equity program and/or a discretionary annual cash incentive program, with awards determined based on individual performance, role scope, market considerations, and overall company results, per the applicable plans.

Equal Opportunity
Diversity strengthens everything we build. We are proud to be an equal opportunity employer and are committed to providing an inclusive workplace for all. We consider all qualified applicants without regard to race, color, national or ethnic origin, age, religion, disability, sexual orientation, gender, gender identity or expression, marital status, or any other characteristic protected by applicable state or federal laws and regulations.

Accessibility
We are committed to providing reasonable accommodations for qualified individuals with disabilities. If you need any accommodation to participate in the application process, please contact us at TA-Operations@the company.