GES D&R

Job Title:

• GES D&R - Exterior Trims Requirement
• Experience:
• • 7 - 12 Years
• Qualification:
• • B.E/B.Tech or M.E/M.Tech (Automotive & Mechanical)
• Job Location:
• • Chennai
• Job Description:
• • Provide specialist engineering services for UP/UN Body Functional Trims and Heat Shields —covering design, development, supplier industrialization, validation, PPAP, and launch support through MP-2 and J1+90.
• Core Responsibilities:
• • Milestone and Governance
  • Own FEDE deliverables, gateway readiness, and timing adherence; maintain full DVP traceability and status.
  • Align DVPs with Core Technical Specialists; keep FEDE up to date with proof of completion.
  • Supplier and Change Management
  • Partner with suppliers to forecast milestones, confirm part supportability, and track tool readiness.
  • Lead Concern Release: author changes with detailed scope, timing, and cost; drive approvals and disciplined implementation.
  • Coordinate with interfacing D&R owners to manage impacts and maintain package/attribute integrity.
  • Engineering and Validation Execution
  • Define and execute DV (CAE and physical) and PV plans; commission proto builds/tests when indicated by CAE.
  • Close DV/PV issues with appropriate design/process fixes; verify via re-test/correlation as needed.
  • Maintain and update DFMEA, P-Diagram, and SCCAF based on latest learnings.
  • Industrialization, PPAP, and Launch
  • Lead PPAP through PSW; plan and execute line trials and build events with plants.
  • Resolve design, supplier quality, and manufacturing issues during change implementation up to J1+90.
  • Ensure Launch builds adhere to Global LQOS standards and roles & responsibilities.
  • Reporting and Ways of Working
  • Produce rigorous validation and issue investigation reports (including 8D) to IMG PD standards with complete backup data.
  • Maintain a collaborative, hands-on presence with daily engagement across CFTs, suppliers, and plants.
  • Success Measures (KPIs)
  • Robust, risk-managed program plan; lessons learned applied from prior launches.
  • On-time FEDE/gateway deliverables; zero meeting delays; timely signoffs.
  • CAD proposals delivered to meet design-phase milestones.
  • Zero in-plant defects that should have been caught at supplier signoff.
  • Pre-production build issues: root cause and ICA within 24 hours.
  • Clean launch and field performance with proactive risk mitigation.
• Skill set:
• • CAD/PLM: 3DX/CATIA V6/V5; Teamcenter, Vis Mockup, DMU. Program control: GPDS; FEDE milestones; DVP; Concern Release; 50:50 D&R/CAD. Validation: DV/PV plans; CAE-to-proto; rapid 8D RCA; ICA/PCA closure. Manufacturing/launch: DFM/tooling; PPAP/PSW; line trials; plant support to J1+90. Suppliers/CFTs: Drive suppliers; align D&R/CAE/STA/VOME/Attributes; LQOS; DFMEA, P‑Diagram, SCCAF; proactive risk/Plan‑B.
• Domain Knowledge:
• • Systems and Components
  • UP/UN Body Functional Trims and Heat Shields: package constraints, interfaces, mounting strategies, durability, NVH, and thermal protection near exhaust/powertrain and underbody zones.
  • Materials and construction methods for heat shields (aluminized steel, stainless, multi-layer insulation, embossed/beaded forms) and functional trims (stamped metal, molded plastics, clips/fasteners, adhesives/tapes).
  • Manufacturing and Tooling
  • Stamping/forming/embossing, piercing, clinching/riveting, spot welding, adhesive bonding, and tape applications; design for assembly and service access.
  • Tooling feasibility, draw/bead strategies, flange and hole pattern optimization, tolerance stack-ups, and GD&T appropriate for body-in-white and underbody environments.
  • Validation Methods
  • CAE: thermal mapping, conduction/convection/radiation assessments, modal/vibration for rattle robustness, durability.
  • Physical testing: thermal soak, hot-spot verification, rattle/buzz, corrosion/stone-chipping exposure, vibration/durability, fit-and-finish checks.
  • DVP&R planning, correlation strategies, acceptance criteria, and re-test closure protocols.
  • Quality, Launch, and Compliance
  • APQP/PPAP/PSW, control plans, process capability considerations, and run-at-rate expectations.
  • Ford processes and standards: GPDS, FEDE, LQOS, DFMEA, P-Diagram, SCCAF, Concern Release, and AIMS.
  • Build phases and events: DCV builds, pre-production/line trials, MP-2, and support through J1+90.
  • Attribute alignment: thermal, NVH, durability, corrosion, and serviceability requirements at vehicle level.
  • Cross-Functional Ecosystem
  • Collaboration with D&R, CAE, STA, VOME, Attribute Teams, and Global/Regional engineering; effective supplier development and escalation paths for timing, quality, and cost Purpose.