Senior Engineer, Chassis Systems

Position Overview

The Senior Engineer, Chassis Systems is responsible for ensuring chassis manufacturing quality through successful execution and continuous improvement of chassis system assembly, wheel alignment processes, torque-controlled joint assembly, wheel and tire installation, and end-of-line vehicle validation.

The role serves as the primary technical interface between Vehicle Engineering, Manufacturing, Quality, Controls, Supplier Quality, Service Engineering, and Plant Operations to ensure all vehicles meet alignment, handling, safety, and customer satisfaction targets before shipment.

Responsible for sustaining engineering after initial product launch. This includes design and release of new parts as required such as to improve quality or the assembly process. Working with core engineering to ensure parts meet all design and validation requirements.     

Key Responsibilities

Chassis System Assembly Ownership

• Serve as plant technical lead for chassis assembly operations including front and rear suspension modules, steering system installation, brake system installation, wheels and tires, subframe marriage processes, spring/damper/air suspension assembly, and steering gear/tie rod/knuckle assembly.
• Ensure chassis assembly processes achieve safety, quality, throughput, and cost objectives.
• Partner with Manufacturing Engineering to develop and optimize assembly sequences, tooling, ergonomics, and workstation layouts.
• Support assembly process validation during prototype, pilot, and production builds.
• Investigate and resolve assembly-related concerns including part fit-up issues, excessive installation force, dimensional variation, and fastener accessibility concerns.
• Lead root cause analysis of manufacturing defects resulting from chassis assembly processes.

Joint Tightening & Fastening Integrity

• Own production issue resolution related to chassis joint integrity and torque-controlled assembly processes.
• Support tightening strategy, torque traceability, tool capability, process controls, and fastener accessibility improvements.
• Partner with Manufacturing Engineering, Controls, and Quality to improve joint quality and reduce rework.

Wheel Alignment & Vehicle Geometry

• Serve as plant technical lead for front and rear wheel alignment, camber, caster, toe, thrust angle, ride height settings, ClearVision performance, pull/drift performance, and steering wheel centering.
• Support optimization of automated wheel alignment stations, alignment equipment, and plant tooling.
• Establish robust alignment specifications and process controls.
• Investigate alignment-related customer concerns and warranty claims.
• Drive reduction in wheel alignment variability across production.
• Support development and improvement of alignment stations, ride-height measurement systems, steering angle verification, pull/drift audits, and ClearVision audits.
• Lead troubleshooting of end-of-line equipment and process failures.

Wheels, Tires & End-of-Line Quality Validation

• Serve as technical owner for wheel assemblies, tire fitment, wheel balancing, tire pressure process controls, and assembly variation management.
• Support end-of-line vehicle validation activities for chassis-related performance, geometry, handling, and customer satisfaction targets.
• Support production launch readiness, issue tracking, corrective actions, and continuous improvement activities.

Sustaining Engineering

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

Skills

• Deep understanding of wheel alignment theory, tire behavior, steering systems, chassis fastening systems, vehicle handling fundamentals, and chassis system assembly processes.
• Working knowledge of wheel alignment, chassis integration, manufacturing engineering, quality engineering, and vehicle launch support.
• Hands-on knowledge of GD&T, root cause analysis, DFMEA, PFMEA, statistical process control, and production issue resolution.
• Experience or familiarity with Duerr alignment equipment, Atlas Copco tightening systems, torque traceability systems, and Minitab.
• Knowledge of vehicle pull, drift, ClearVision, and steering performance assessments.
• Strong technical ownership, data-driven decision making, continuous improvement mindset, and manufacturing/field-quality orientation.
• Excellent communication skills across Vehicle Engineering, Manufacturing, Quality, Controls, Supplier Quality, Service Engineering, and Plant Operations.
• Six Sigma Black Belt, Green Belt, Shannin RedX or other equivalent problem-solving methodology. 
• Experience in full life cycle development from concept to prototype to full production.
• Ability to create testing plan and conduct / coordinate physical tests to prove out design concepts and ensure performance targets are being 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 field.
• 5+ years of automotive engineering experience.
• Experience in one or more of: vehicle dynamics, wheel alignment, manufacturing engineering, chassis integration, quality engineering, or vehicle launch support.
• Strong knowledge of wheel alignment theory, tire behavior, steering systems, chassis fastening systems, vehicle handling fundamentals, GD&T, root cause analysis, DFMEA/PFMEA, and statistical process control.
• Strong hands-on troubleshooting skills.
• Experience with 3D CAD system such as CATIA or similar software.
• Design release engineering experience including engineering change management and project management experiences.