Lead Engineer - Bench Level Testing

Overview

Lead Engineer - Bench Level Testing Responsibilities

Roles and Responsibilities:

1. Test Planning and Strategy Development:

- Lead the development and execution of comprehensive test plans for body, chassis, and interior perimeter systems.

- Define testing scope, objectives, methodologies, and criteria for performance, safety, and durability testing.

- Collaborate with cross-functional teams to identify and prioritize test requirements based on customer specifications, industry standards, and regulatory requirements.

2. Test Setup and Configuration:

- Oversee the setup of test rigs, benches, and vehicles for conducting physical and simulated tests.

- Ensure the proper calibration and configuration of testing equipment for accurate data collection and analysis.

- Supervise the integration of vehicle components (body, chassis, interior systems) into test rigs.

3. Test Execution:

- Lead bench-level testing of body structures, chassis components (suspension, braking systems, etc.), and interior perimeter (dashboard, seats, safety features, etc.).

- Execute durability, crashworthiness, crash simulation, vibration, and fatigue tests to assess performance under various environmental and operational conditions.

- Conduct assessments of vehicle behavior during extreme conditions, including temperature, humidity, and dynamic loads.

4. Data Collection and Analysis:

- Oversee the collection of test data from sensors, accelerometers, strain gauges, and other monitoring systems.

- Analyze test results to identify areas of improvement, failure modes, or design optimization opportunities.

- Use CAE (Computer-Aided Engineering) tools and simulation software to correlate bench testing results with virtual simulations.

5. Cross-Functional Coordination:

- Coordinate with design, engineering, manufacturing, and quality teams to ensure that testing aligns with the vehicle development process and production timelines.

- Work closely with material engineers and suppliers to ensure that body, chassis, and interior materials meet required performance standards.

- Provide technical guidance and mentorship to junior engineers and technicians involved in testing activities.

6. Root Cause Analysis and Problem Solving:

- Lead the investigation and root cause analysis of failures during testing (e.g., structural failures, performance degradation).

- Collaborate with design teams to implement corrective actions and drive design modifications based on test findings.

- Ensure that improvements are incorporated into future test plans or production vehicle designs.

7. Compliance and Standards Adherence:

- Ensure that all tests comply with global automotive safety, regulatory standards, and internal quality guidelines (e.g., crash test standards, ISO, SAE).

- Monitor the impact of regulatory changes on testing requirements and implement necessary adjustments.

- Prepare reports and documentation to support certifications and compliance audits.

8. Documentation and Reporting:

- Lead the preparation of comprehensive test reports, including test setups, methodologies, results, and recommendations.

- Present findings to senior leadership and stakeholders, providing insights into vehicle performance and potential risks.

- Maintain thorough documentation of test procedures, data, and modifications for future reference and continuous improvement.

9. Cost and Resource Management:

- Manage test resources, budgets, and timelines to ensure efficient execution of testing activities within allocated budgets.

- Optimize the use of testing equipment and facilities to maximize productivity while maintaining quality standards.

- Identify cost-effective solutions for bench testing without compromising accuracy and safety. Qualifications

B.E/B.Tech in Mechanical/Automotive/Production Essential skills

- Expertise in testing techniques, including structural, performance, and durability testing.

- Strong knowledge of automotive standards and regulations (e.g., crash testing, safety standards).

- Proficiency in CAD/CAE software for simulation and data analysis.

- Strong problem-solving, analytical, and troubleshooting skills.

- Leadership skills with the ability to manage a team and communicate with multiple stakeholders. Desired skills

Experience

8 - 12 years experience