Advanced Differentials Engineer

The Differentials Senior DRE acts as a driveline/Axles Differentials expert of all types i.e. Open, Mechanical (Clutches/Helical) Limited Slips (mLSD), Electromagnetic/Hydraulic Limited Slips (eLSD) and Locking Diffs. A successful candidate will collaborate with dynamic engineers to support the design, development, Validation and Manufacturing of both externally purchased and in-house manufactured Differentials and internal components such as Diff case, gears, Shafts, Clutch pack, motors, sensors, actuation mechanisms. This role demands an in-depth expertise in Technology, Design/analysis, transfer functions, validation test designs, manufacturing processes for Differentials, gear technology, Axles architectures and Differential interfaces, sub-component interactions, lubrication flow strategies, efficiency, and NVH characteristics. Key responsibilities include leading programs and supporting engineers across multiple programs to ensure the delivery of a balanced, integrated, and validated system that meets stringent functional, performance, and durability requirements. The Differential Expert will leverage their expertise to optimize the designs and contribute innovative solutions for improved performance and reliability.

Job Responsibilities include (but not limited to):

• Lead the design and development of Open/mLSD/eLSD/e-Locker Differentials systems, subsystems and components

• Technical Support: Provide expert technical support to resolve issues and answer inquiries related to gear reducer systems.

• Supplier Design Approvals: Drive approvals for supplier design selection through appropriate assessments and adherence to engineering best practices.

• Collaboration: Work closely with key stakeholder teams such as NVH (Noise, Vibration, and Harshness), durability, vehicle dynamics, packaging, and manufacturing to ensure seamless integration and performance.

• Best Practices and Documentation: Create, implement, and manage engineering best practices, including the development and maintenance of core DFMEA (Design Failure Mode and Effects Analysis) and DVP (Design Verification Plan) documents related to Differentials.

• Continuous Improvement: Proactively seek opportunities to improve Differential designs, processes, and products through innovative solutions and best practices.

• Technical Specification: Assist engineers in generating detailed system and sub-system technical specifications (SSTS/TTS) to ensure functional objectives are met. Manage these documents to ensure alignment of requirements with the supplier base.

• Mentoring: Mentor other Differential DRE's on make vs buy trade-offs responsibilities and their role in the PSDP process. Clearly define and communicate the roles and responsibilities of DRE in the ownership of PSK's, ensuring thorough understanding and accountability.

• Total Warranty Cost Reduction: Identify areas of improvement to reduce total warranty costs and propose technical solutions.

• Industry Competitiveness: Ensure the gear reducer's competitiveness in terms of mass, efficiency, torque, power, NVH, and cost.

• Intellectual Property Development: Propose the development of intellectual property (e.g., patents, NDAs, EBPs) because of product innovation.

Basic Qualifications:

• Bachelor's degree in Applied Physics, Mechanical / Electrical Engineering or related degree field

• A minimum of 8 years of experience working on Differentials (Open, mLSD, eLSD, Locking)

• Strong analytical and troubleshooting skills to resolve technical issues and optimize designs

• In-depth knowledge and expertise in Differentials design/analysis & Transfer functions, gear technology, Diff/Axles architectures, sub-component interactions, lubrication flow strategies, efficiency, and NVH characteristics

• Ability to author system/component level requirements

• Working knowledge of Analytical and Experimental Validation tools for Differentials components, sub system and systems

• Strong interpersonal communication, adaptable to work on multiple programs, proactive and driven for results

• Understanding root cause analysis tools like fish bone analysis, Is-Is not, 3L5Y, Red X, etc.

Preferred Qualifications:

• Master of Science degree in Applied Physics or Mechanical / Electrical Engineering

• 10 years of experience working on Differentials (Open, mLSD, eLSD, Locking)

• DFSS green belt certification.

• Shannin black belt certification

• Experienced in Analytical and Experimental Validation tools for Differentials components, sub system and systems.

• Demonstrated working level experience in decomposing intended functions into requirements.

• Working experience with in-vehicle problem diagnosis and NVH evaluations.

• Knowledge of CAE/CFD to collaborate with virtual analysis teams.

• Assembly and computer aided design (NX / CATIA).

• Experience with Design Failure Mode & Effects Analysis (DFMEA).

• Experience with Design Verification Plan & Report (DVP&R).

• Experience with Geometric Dimensioning and Tolerancing (GD&T).

• Critical character traits to ensure success: Strong leadership, Action Oriented, Dealing with Ambiguity, Customer Focus, Problem Solving and cradle to grave ownership mind set and ability to work independently with least amount of direction.