DRE Suspension Shock absorber

Role & responsibilities

Role: DRE - Chassis Suspension Shocks & Tune-able Components design and development.

• Engineering, Design & Development of Chassis suspension tunable components. (shock absorber, Strut assembly, springs, stabilizer bars, link stay bar, top mounts, bushing & strut child parts like jounce bumper ) for current & new program. Development of Suspension module, Corner module and Strut module.
• Define Component development process and timeline to meet vehicle functional objectives, cost and timing.
• Shock absorber & its child parts Design & Development: Develop requirement matrix, Source package, Technical review with supplier, Suppler evaluation, DVP&R finalization, lead development, supplier process review, error proofing, tooling and fixture/ gauges review, material sign off, PPAP.
• Supplier tech review & process development to suit vehicle assembly process. (Define & approve Assembly fixture, in process inspection method, error proofing of lines, review of control plan and PFMEA)
• Review part assembly process, and torque tool & process review to achieve required torque joints.
• Periodic review with supplier / SQE on continuous conformance.
• Plant technology and vehicle build support at module supplier and vehicle assembly plant for all Suspension Structural Components.
• Review test cost and Test plan. Update DV & PV test completion status in line with program milestones.
• Root cause assembly issues arising due to suspension at plant and at module supplier.
• Follow STLA product development processes. Creating Source package, develop durability and functional objectives for Suspension Components. Supplier readiness evaluation, Technical review, Tool development and time plan review to meet program deliverables for Parts availability, DV, PV tests.
• Guide CAE team for analysis of above Chassis components to meet required fatigue life cycle, dynamics & NVH.
• Carry out design calculations to meet as needed to meet vehicle functional objectives.
• Interpret road load data and guide CAE team to carry out fatigue load cases, understand the right boundary conditions and understand the CAE results and analyze the component level fatigue life.
• Work closely with SQE and supplier for resolving part development challenges, ensure timely KPIs are met for program quality gates.
• Understand vehicle/sub system functional objectives, inter dependencies and study the packaging, serviceability and cost implications.
• Address component, assembly & vehicle Field Early Warranty issues with quality & service team.
• Working closely with cross functional teams like materials, CAE, testing, product center of competency, service, warranty and supplier quality.
• Drive value optimization initiative and meet target cost savings. And support DFSS projects in Suspension.
• Develop new local suppliers to meet functional targets & cost.

Competitive bench marking & innovation projects.

Essential

• Minimum 3 to 8 years of hands-on experience with automotive OEM or Tier1 company of shock absorbers with design, development, manufacture, testing, tuning of Shock absorbers for passenger car application.
• Spring and damper design, Jounce bumper, bushing stiffness calculation. Calculate stab bar torsional stiffness, develop suitable stiffness strategy for jounce bumpers, understand suspension geometry and kinematic & compliance will be an additional skill set required.
• In-depth experience on Suspension alignment, assembly process, Module development, product development process, supplier evaluation, tech review, DFMEA, DVP&R, control plan, PFMEA, PPAP.
• Root cause analysis (Proactive & reactive methods) for parts under development and field return/warranty.
• Knowledge of DFSS methodology for design and reactive root cause analysis methods. (Shainin, DOE).
• Proficiency in CATIA / UG NX/ Team Center / PLM.
• Good understanding of functional science of Chassis subs systems for fatigue, NVH, handling and stiffness.
• Excellent written and verbal communication skills

Preferred Experience

• Vehicle assembly process knowledge and system and component tooling and process experience.
• Process knowledge of casting, sheet metal and forging.
• Simulation of manufacturing processes (sheet metal forming, casting-mold fill simulation)
• Knowledge of various chassis subsystems and Vehicle dynamics.