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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.
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