Job Title: Lead Engineer – PTSE Components (Fuel Systems Focus)
Location: Warwickshire
Employment type: Permanent/Contract
We are seeking a highly skilled and experienced Lead Engineer to lead the design, release, and development of PTSE components, with a focus on fuel systems. You will ensure these components meet performance, safety, cost, and quality standards, while managing the entire lifecycle from design through production.
Key Responsibilities:
Design & Development:
* Lead the creation of detailed CAD models and engineering drawings for PTSE fuel system components (fuel tanks, pumps, injectors, fuel lines, etc.).
* Provide design direction and approve engineering drawings for fuel system components.
* Lead root cause analysis and corrective actions for design-related issues in fuel system components.
* Complete design validation through CAE simulations, prototyping, and physical testing, specifically for fuel system components.
* Ensure fuel system designs comply with industry standards, regulatory requirements (e.g., EPA, CARB), and internal specifications.
* Research emerging technologies and materials to enhance fuel system performance (e.g., new fuel types, hybrid technologies).
* Drive cost reduction and weight optimisation initiatives without compromising safety, quality, or fuel efficiency.
* Contribute to design reviews and lessons-learned sessions related to fuel system development.
Release Management:
* Manage the Bill of Materials (BOM) and part release processes for fuel system components using PLM systems (e.g., 3Dx or Teamcenter).
* Coordinate with suppliers and manufacturing teams to ensure timely release and readiness for production of fuel system components.
* Maintain documentation for design changes, approvals, and release milestones specific to fuel systems.
Programme Delivery:
* Collaborate with cross-functional teams, including programme teams, manufacturing, purchasing, quality, and development teams, to ensure successful fuel system integration into the overall vehicle design.
* Track programme timelines, budgets, and deliverables to ensure on-time delivery of fuel system components.
Supplier Management:
* Collaborate with suppliers to ensure timely delivery of fuel system components that meet engineering specifications and quality standards.
* Monitor supplier performance using KPIs and initiate corrective actions where necessary.
* Support sourcing decisions through technical assessments and risk evaluations specific to fuel systems.
* Facilitate cross-functional alignment between engineering, purchasing, and supplier teams to resolve issues and optimise fuel system delivery.
* Ensure supplier compliance with programme milestones, cost targets, and launch readiness requirements for fuel systems.
Experience & Qualifications:
* Degree qualified in Mechanical Engineering, Automotive Engineering, or related field.
* Significant experience in automotive fuel systems, including components such as fuel tanks, pumps, injectors, lines, and related subsystems.
* Full UK driving licence (for roles based onsite in the UK).
* Strong understanding of materials, manufacturing processes, and fuel system technologies in automotive applications.
* Experience with FEA, DFMEA, and design validation tools specific to fuel systems.
* Familiarity with PLM systems (e.g., 3Dx, Teamcenter, TRM).
* Excellent problem-solving, communication, and project management skills.
* Demonstrated commitment to customer satisfaction, teamwork, integrity, growth, and impact.
Failure Mode Avoidance & Problem Solving:
* Lead complex engineering and process investigations using the 8D framework to identify and eliminate root causes of fuel system-related issues through data-driven analysis.
* Apply Failure Mode Avoidance (FMA) techniques, including containment, warranty mitigation, and recurrence prevention, specifically for fuel system components.
* Use structured problem-solving tools to validate cause/effect relationships, incorporating measurement system capability and process mapping in fuel system design.
* Implement robust, permanent solutions and control methods to sustain improvements across fuel system development.
* Deliver cost-effective, resilient outcomes through effective issue management methodologies.
Systems Engineering:
* Apply systems thinking and engineering principles to address challenges specific to automotive fuel systems.
* Utilise systems engineering methodologies across the design, integration, and verification stages of fuel system components.
* Demonstrate expertise in Requirements Management, Systems Modelling, Test Authoring, Testing, Workflow, and Configuration Management for fuel systems.
* Deliver integrated fuel systems that meet customer and regulatory requirements using appropriate toolsets.
* Create design rules and standards for fuel systems and associated components.
Geometric Dimensional Control:
* Decompose complex fuel system designs into conceptual assembly sequences, defining key locations and fixing strategies.
* Manage variation and tolerance using statistical analysis and six degrees of freedom principles in fuel system components.
* Leverage engineering toolsets to process measurement data and ensure high-quality fuel system engineering releases.
* Apply digital tools to support robust fuel system release and maturation throughout launch phases.
Commodity Planning:
* Interpret Programme Assumptions, ReUse strategies, and Commodity Plans to support fuel system feature delivery.
* Navigate the critical path of fuel system commodity delivery in alignment with the Complex Commodity Delivery System (CCDS) process.
* Apply all phases of Advanced Product Quality Planning (APQP) and Engineering Build Event Readiness (EBER) for fuel systems.
Cost & Budget Management:
* Analyse financial data across multiple sources to identify risks and opportunities for cost optimisation specific to fuel systems.
* Use financial tools to deliver key performance indicators (KPIs) across engineering functions for fuel system projects.