Sr. Suspension Engineer

About the Role
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.
Responsibilities include sustaining engineering after initial product launch, which entails the design and release of new parts as required to improve quality or the assembly process while ensuring 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 monitoring strategies using production and warranty data.

Sustaining Engineering

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

Skills

• Deep understanding of suspension systems, structural chassis components, and vehicle dynamics fundamentals.
• Strong working knowledge of durability engineering, manufacturing processes, GD&T, and tolerance stack-up analysis.
• Proficiency with structured root cause analysis and corrective action methods.
• Working knowledge of DFMEA, PFMEA, and DVP&R processes.
• Hands-on troubleshooting mindset with the ability to support production floor issue resolution.
• Cross-functional leadership and communication skills across Engineering, Manufacturing, Quality, Supplier Quality, Purchasing, and Plant Operations.
• Ability to support suppliers and internal teams through launch readiness, containment, corrective action, and continuous improvement.
• Excellent communication skills across Vehicle Engineering, Manufacturing, Quality, Controls, Supplier Quality, Service Engineering, and Plant Operations.
• Six Sigma Black Belt, Green Belt, Shanin 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 prove out design concepts and ensure performance targets are achieved.
• Proficient in reading and interpreting GD&T. Coordinate virtual engineering and physical validation testing activities for your designs.
• Hands-on practical experience in prototype assembly and production assembly with the willingness to assemble your own parts.
• Be able to derive clamp load and torque values for critical joints.

Minimum Qualifications

• Bachelor's degree in Mechanical Engineering, Automotive Engineering, Manufacturing Engineering, or a related technical field.
• 5+ years of experience in automotive engineering, suspension systems, structural engineering, manufacturing engineering, or vehicle integration.
• Experience supporting vehicle launches and production operations.
• Strong understanding of suspension systems, structural chassis components, vehicle dynamics fundamentals, durability engineering, manufacturing processes, GD&T, root cause analysis methodologies, DFMEA, PFMEA, and DVP&R.
• Strong hands-on troubleshooting skills.
• Excellent communication and cross-functional leadership abilities.
• Experience with 3D CAD systems such as CATIA or similar software.
• Design release engineering experience including engineering change management and project management experiences.

Compensation & Benefits
The company offers a comprehensive and competitive benefits package 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 paid time off, and salaried/exempt employees accrue up to 160 hours paid time off. Eligible employees may also participate in the company's equity program and/or a discretionary annual cash incentive program. Incentive and equity awards, if applicable, are determined based on individual performance, role scope, market considerations, and overall company results, in accordance with the terms of the applicable plans.

Equal Opportunity
The company believes diversity strengthens everything we build and is proud to be an equal opportunity employer 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
The company is 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 the designated email address for accommodation requests. Note that this address is solely for accommodation requests and is not monitored for job applications or resume submissions.

Candidate Data Privacy
By submitting your application, you understand and agree that your personal data will be processed in accordance with the company's Candidate Privacy Notice.