Mechanical Engineer I

About the role

The Mechanical Engineer I is responsible for the design, development, documentation, testing, and evaluation activities for components, sub-assemblies, and finished goods products that meet the cost, performance, and timeliness requirements defined within ESG’s Product Planning Process (P3 Process). This person will investigate, develop, and implement new technologies, tools, and processes, solving problems through original thinking and ingenuity.

Responsibilities

• Design and develop products, assemblies, and components that meet or exceed ESG’s stringent quality, cost, performance, and schedule requirements.
• Create new vehicle-specific parts and test fit parts onto cars, trucks, and other vehicles.
• Disassemble and measure vehicles using hand tools or a 3D scanner.
• Fit check parts onto various vehicles/applications.
• Support Label Modification projects as defined within ESG’s P3 Processes.
• Review and approve mechanical and finished goods drawings.
• Write assembly instructions (AIs), work instructions, and equipment maintenance procedures.
• Develop production jigs, assembly fixtures, and crimping tools for domestic and international manufacturing.
• Complete finished goods first article reports (FARs).
• Create Control Plan, Process FMEA, Process Flow Diagram, and PPAP documentation.
• Perform finished goods product verification, qualification, and validation testing.
• Incorporate fundamentals of Design for Manufacture and Assembly (DFMA).
• Develop and maintain detailed and accurate Bills of Materials (BOMs) and Approved Vendor Lists (AVLs) for sub-assemblies and finished goods products.
• Ensure integrity of mechanical design and product development processes.
• Analyze, evaluate, and recommend system improvements to reduce product design cycle times.
• Resolve engineering and technical issues quickly.
• Facilitate consistent and predictable alarm and light production, including outsourcing PCA testers, light output testers, flash rate testers, speaker sweep stations, and alarm test boxes.
• Participate in Component Part Qualification (CPQ) process for speakers, drivers, LEDs, and mechanical parts.
• Actively participate in ESG’s Change Request (CR/ECN/DCN) process.

Requirements

• B.S.M.E. degree, or equivalent experience.
• SolidWorks (or equivalent CAD software) training or experience (modeling, assembly, and drawing creation).
• Good communication skills, both written and verbal, including the ability to prepare, present, and discuss project-related plans, requirements, and test results in a team-based work environment.
• Working knowledge of Microsoft Office including Word, Excel, PowerPoint, Outlook, and Project (intermediate skill level preferred in Excel).

Qualifications

• SolidWorks surfacing modeling, sheet metal design, and modeling for injection molding.
• Experience with SolidWorks Simulation.
• Experience working in an install bay, upfitting vehicles, or installing aftermarket parts/electronics onto vehicles.
• Experience using a manual mill, lathe, drill press, bandsaw, and other shop tools.
• Experience rapid prototyping parts, fixtures, and products, both subtractive (CNC) and additive (grown).
• Understanding of industry document control practices and ability to adhere to ESG’s documentation processes.
• Experience or good understanding of optical design for LEDs.
• Good understanding of LED, speaker, and driver theories of operation.
• Good understanding of electrical and electronic systems and components.
• Understanding of manufacturing processes, production yield metrics (process capability, gage R&R), and production test procedures (alarms and lights preferred).
• Good understanding of test techniques for product validation, product verification, and Design of Experiments (DOE).

Physical demands

While performing the duties of this job, the team member is regularly required to talk or hear. The team member frequently is required to stand; walk; use hands to finger, handle or feel; and reach with hands and arms.