Design Release Engineer - Exhaust Manifolds

The Design Release Engineer for powertrain exhaust manifolds is responsible for the design, development, and technical leadership in the creation, validation, and release of exhaust manifolds and sub-components Stellantis' vehicles. The role involves driving the design through all phases of the product lifecycle, including design concept, engineering validation, and production release through PPAP (Production Part Approval Process). Exhaust manifold sub-components may include seals, fasteners, spacers, etc...

Key Responsibilities:

Design & Development:

• Lead the design of exhaust manifold components, ensuring alignment with vehicle and powertrain requirements.
• Develop and refine concepts for exhaust manifold components, based on functional, safety, and performance requirements.
• Support CAD modeling, FEA (Finite Element Analysis), and other design validation methods to ensure structural and functional integrity, and compliance with standards.
• Collaborate with other engineering teams to integrate exhaust manifold components into the overall powertrain architecture.

Release & Program Management:

• Manage design release activities from early concept through production, including the timely completion of B-Sample, C-Sample, X0, X1, X2, and X3 milestones.
• Own the Bill of Materials (BOM) and Engineering Change Notices (ECNs) for powertrain exhaust manifold components.
• Ensure all parts meet quality, cost, and timing requirements.
• Drive the Production Part Approval Process (PPAP) for powertrain exhaust manifold components, ensuring compliance with all regulatory and customer specifications.
• Coordinate with cross-functional teams, including manufacturing, suppliers, and quality, to ensure the successful release and implementation of designs.

Technical Guidance & Problem Solving:

• Provide technical leadership and support during the development and production stages to resolve design issues, material selection challenges, and process-related problems.
• Lead DFMEA (Design Failure Mode and Effects Analysis) and other risk assessment activities to ensure design robustness and mitigate potential issues.
• Participate in the development of testing strategies for powertrain exhaust manifold components.

Cross-Functional Collaboration:

• Work closely with suppliers to ensure design feasibility, cost competitiveness, and manufacturability of powertrain exhaust manifold components.
• Collaborate with validation teams to define and implement validation testing, ensuring powertrain exhaust manifold components meet functional and performance metrics.
• Partner with vehicle integration teams to ensure proper fitment, safety, and integration of powertrain exhaust manifold components into the overall vehicle platform.

Documentation & Reporting:

• Develop and maintain engineering documentation, including design specifications, drawings, test plans, and validation reports.
• Ensure that all technical documentation is up-to-date and aligns with program timelines and PPAP requirements.
• Report on project status, timelines, and risk assessments to senior management and stakeholders.

Basic Qualifications:

• Bachelor of Science degree in Mechanical Engineering or related degree field
• A minimum of 5 years of relevant experience working with powertrain structural components, specifically exhaust manifolds, engine blocks, and cylinder heads
• Understanding of engine structural components and related manufacturing processes, specifically steel and aluminum casting and machining processes.
• Understanding of product development documentation such as, DFMEA and DVP&R
• Understanding of Mechanics of Materials, Sealing systems, CAE Analysis, and GD&T
• Experience in selecting materials and manufacturing methods for structural and sealing components.
• Ability to author system/component level requirements
• Strong interpersonal communication, team/leadership skills/experience
• Strong oral and written communication skills
• Strong project management skills/experience

Preferred Qualifications:

• Advanced degree in Mechanical Engineering from ABET accredited school or equivalent
• Working experience in creation and execution of validation plans
• Critical character traits to ensure success: Action Oriented, Dealing with Ambiguity, Customer Focus, Problem Solving.
• Working experience with 3D cad programs, preferably Siemens NX
• 8+ years of relevant experience working with design and manufacturing of powertrain structural components, specifically exhaust manifolds, engine blocks, and cylinder heads