Sr. Design Engineer

Develop documentation regarding project scope, requirements, feasibility, and engineering workplan. Work directly with product engineering to capture needs and translate these into an executable project. Lead mechanical design and development activities with some guidance from engineering manager. Provide technologies that are manufacturable, cost effective, and meet product engineering requirements. Develop and communicate mitigation plan for areas of risk. Plan and lead Design Failure Mode and Effect Analysis (DFMEA), Finite Element Analysis (FEA), Tolerance Analysis, and other theoretical studies. Lead prediction correlation efforts. Create feature models and drawings using GD&T methodology (including datum selection, dimensioning and tolerancing). Prepare and follow Engineering Change Requests (ECR) per document control procedures. Develop test plans, including Design Verification Plan and Report (DVP&R) to validate performance. Analyze test results using statistical methods including Design of Experiments (DOE), Hypothesis Testing, and Capability Studies. Lead root cause analysis utilizing structured problem-solving methods (such as 8D, 5 Why, and Fishbone). Provide technical mentoring for a wide variety of engineering topics, tools, and processes. Lead and coordinate the preparation and presentation of technical reviews with internal and external teams.

Full time employment, Monday - Friday, 40 hours per week.

Bachelor’s degree in Mechanical Engineering or a related field and four (4) years of experience with plastic resin and copper alloy materials.

Must have four (4) years of experience in all of the following:

• Electromechanical Engineering; and
• Manufacturing processes including at least one of the following: terminal stamping, copper alloy plating, injection molding, or wire sealing function.

Must have two (2) years of experience in all of the following:

• Creating mechanical designs related to terminal cavity electrical, mechanical, and sealing functions;
• Mitigating fit and form function risks in terminal cavity technologies utilizing Geometric Dimensioning and Tolerancing (GD&T) based on failure modes identified using Design Failure Mode and Effect Analysis (DFMEA); and
• Updating DMFEA based 8D methodologies for terminal cavity functions.

Telecommuting permitted up to 1 day per week.

International travel required up to 10%. Domestic travel required up to 10%.