Test Engineer

Safety Laboratories Department Position

The Safety Laboratories Department (SLD) is part of the Vehicle Evaluation & Verification (VEV) organization, responsible for safety testing, including component, subsystem, and full vehicle crash testing to develop vehicle safety systems and demonstrate compliance to U.S. and global government safety regulations, as well as internal guidelines and requirements. The crash test engineer coordinates full-vehicle crash tests for regulatory and corporate safety/public design guideline requirements. They interface with requesting engineers and witness authority to verify test objectives and requirements and ensure all aspects of testing requirements are being met. They lead a team of technicians with test mode impact point and vehicle alignment. They coordinate photographic technicians and sensor supplier support timing/process. They work with dummy lab personnel to ensure that proper procedures are being followed for dummy positioning or to meet the customer specific needs. They record all dummy measurements using the Coordinate Measuring Machine (CMM) and software and generate Measurement Report for the customers. They conduct quality assurance activities, reviewing test data, investigating and reporting data anomalies. They complete post-test assessments and high-speed video review. They document vital observations pertinent to regulations and corporate requirements. They generate final test report, including auto-processing and highlight process deviations when required. They provide written comments for observations and results from required engineering evaluations. They generate and compile data from various data sources to be included in final test report. They complete post-test regulatory and design requirement evaluations, including door open-ability, restraints retention, fuel system integrity, windshield retention and intrusion, etc. They communicate preliminary results to test requestors. They provide technical direction and support for crash facilities (winch drive, barrier wall, fuel roll rig), mechanical equipment (mobile barrier carts, moving tables, fixtures), and electrical equipment (data acquisition system, transducers, coordinate measuring machines). They help with the use of specialized or unique equipment, tools and configurations. They resolve operational issues and implement measures to prevent recurrence. They work closely with lab personnel (unit supervisor, technologists and technicians) to identify and implement actions to improve operational quality, cost and timing. They provide support for the function and configuration of test control software and automated data processing tools. They assist with the maintenance and monitoring of lab metrics. They work closely with Crash program requesters, the Automotive Safety Office (ASO), and other Safety Lab Department (SLD) test engineers to support vehicle program testing. They help resolve test capability and performance concerns and assess data for anomalous behavior. When necessary, they complete root-cause analysis, non-conformance communication and response plans; document as 5D's when appropriate. They attend daily crash barrier scheduling meeting, provide input to scheduling and report out status/issues for individual tests. They work with management and technician staff to deliver work schedule or recover from delays. They provide vital, timely support for the crash barrier testing and dummy lab operations to ensure the highest quality and no lost data resulting from preventable faults or errors.

• B.S. in engineering from an accredited institution, Mechanical or Electrical strongly preferred

• Highly organized; able to manage multiple long and short term projects effectively

• Strong leadership skills for cross-functional cooperation and issue resolution

• Strong MS Office suite and computer skills to create and publish test instructions, logs and reports.

• Excellent written and oral communication skills

• Ability to work off shifts and weekends as necessary to support testing milestones

Preferred:

• 1+ years of experience in a Crash Safety Testing environment.

• Knowledge of various types of full-vehicle crash modes (frontal, side, rear, drop), test objectives and complexity (sensor, fuel system, occupant protection, witness)

• Knowledge of various transducers (accelerometers, angle rate sensors, pressure switches, etc.)

• Knowledge of various ATD types and positioning procedures

• Applied understanding of Measurement Uncertainty, Equipment Calibration, Data Acquisition, Control Systems Fundamentals, SPC, QOS, FMEA, G8D and 6-Sigma skill set or certification

• Ability to develop business cases and presentations to upper management

• Demonstrated experience leading capital improvement projects ($100k minimum)

• Personal vehicle for travel to and from work location

Other Qualities to look for:

• Motivated

• Self-starter

• Willing to help where needed

• Attention to details

• Calm under pressure

• Positive, Can-Do attitude

• Effective and professional communication skills

• Problem solving skills

• Good work ethics