Senior Engineer, Chassis Systems

About the Role
The Senior Engineer, Chassis Systems is responsible for ensuring chassis manufacturing quality through successful execution and continuous improvement of chassis system assembly, wheel alignment processes, torque-controlled joint assembly, wheel and tire installation, and end-of-line vehicle validation. This role serves as the primary technical interface between Vehicle Engineering, Manufacturing, Quality, Controls, Supplier Quality, Service Engineering, and Plant Operations to ensure all vehicles meet alignment, handling, safety, and customer satisfaction targets before shipment. The role also encompasses sustaining engineering after the initial product launch, which includes the design and release of new parts as required to improve quality or the assembly process, working with core engineering to ensure parts meet 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, and air suspension 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 and excessive installation force.
• Lead root cause analysis of manufacturing defects stemming from chassis assembly.

Joint Tightening & Fastening Integrity

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

Wheel Alignment & Vehicle Geometry

• Serve as plant technical lead for front and rear wheel alignment, camber, caster, toe, thrust angle, and ride height settings.
• Support optimization of automated wheel alignment stations 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.
• 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, and assembly variation management.
• Support end-of-line vehicle validation activities for chassis-related performance and customer satisfaction targets.
• Support production launch readiness, issue tracking, corrective actions, and continuous improvement activities.

Sustaining Engineering

• Responsible for the design and development of automotive chassis components to deliver high performance in NVH, Durability, and Manufacturability while optimizing cost.
• Work closely with other stakeholders such as Vehicle Safety, Vehicle Dynamics, and more.
• Collaborate cross-functionally with Manufacturing, Design, Product Development, Purchasing, and Suppliers on tool buy-offs and secondary component changes.

Skills

• Deep understanding of wheel alignment theory, tire behavior, steering systems, and chassis fastening systems.
• Working knowledge of quality engineering, vehicle launch support, and chassis integration.
• Hands-on knowledge of GD&T, root cause analysis, DFMEA, PFMEA, and statistical process control.
• Experience with Duerr alignment equipment, Atlas Copco tightening systems, and Minitab.
• Excellent communication skills across various departments.
• Six Sigma Black Belt, Green Belt, Shannin RedX or other equivalent problem-solving methodology.
• Experience in full life cycle development from concept to production.
• Proficient in reading and interpreting GD&T.
• Ability to derive clamp load and torque values for critical joints.

Minimum Qualifications

• Bachelor's degree in Mechanical Engineering, Automotive Engineering, or related field.
• 5+ years of automotive engineering experience.
• Experience in vehicle dynamics, wheel alignment, and manufacturing engineering.
• Strong problem-solving skills and experience with 3D CAD systems like CATIA.
• Design release engineering experience including engineering change management.

Compensation & Benefits
Offers a comprehensive and competitive benefits package including:

• Medical, dental, and vision insurance
• Life and disability coverage
• Paid time off (up to 120 hours for hourly/non-exempt employees; up to 160 hours for salaried/exempt employees)
• Paid holidays and paid sick leave
• 401(k) retirement plan
• Eligibility to participate in an equity program and/or discretionary annual cash incentive program
  Incentives and equity awards are determined based on individual performance and overall company results.

Equal Opportunity
Committed to providing an inclusive workplace for all. All qualified applicants are considered without regard to race, color, or any other characteristic protected by law.

Accessibility
Committed to providing reasonable accommodations for qualified individuals with disabilities.

Candidate Data Privacy
By submitting your application, you agree that your personal data will be processed in accordance with our Candidate Privacy Notice.

To All Recruitment Agencies
Agency resumes are not accepted. We are not responsible for any fees related to unsolicited resumes.