Senior Lead Engineer - Body Shop Fixtures & Automation

The Lead Engineer will lead a team of design engineers responsible for developing BIW assembly fixtures, welding fixtures, robotic end-of-arm tooling (EOAT), pass tables, and related manufacturing tooling systems.

The successful candidate will guide projects through concept development, detailed design, supplier manufacturing, tool buy-off, installation, and production launch. This position requires extensive experience with Siemens NX and Teamcenter, strong knowledge of fixture locating and clamping principles, and the ability to collaborate effectively with cross-functional teams, suppliers, and manufacturing facilities worldwide.

Experience with automotive OEM product development processes, large-scale CAD/PLM data migration initiatives, and global engineering collaboration is highly valued.

Key Responsibilities

Technical Leadership

Lead and mentor a team of mechanical design engineers.
Establish design standards, best practices, and engineering quality processes.
Review and approve fixture designs, layouts, and manufacturing documentation.
Drive continuous improvement initiatives across tooling design activities.

Fixture Tooling Design

Design and develop BIW assembly and welding fixtures.
Lead fixture concept development, detailed design, and manufacturing release.
Apply robust locating and clamping methodologies, including 3-2-1 locating principles.
Develop clamp units, pin units, sensor integrations, and shim strategies.

Automation EOAT Design

Lead design and validation of robotic grippers and end-of-arm tooling.
Perform payload, center-of-gravity, and structural evaluations.
Support pass table, stand, and automated handling equipment design.

Program Execution

Support tooling sourcing, supplier reviews, tryout activities, and tool buy-off.
Coordinate activities with suppliers, manufacturing plants, and program teams.
Manage project schedules, deliverables, risks, and technical issue resolution.

Manufacturing Launch Support

Provide on-site support during prototype, pre-production, and production launches.
Troubleshoot tooling, dimensional, and manufacturing concerns.
Support implementation of corrective actions to achieve launch readiness.

Digital Engineering Data Migration

Participate in or lead CAD and PLM migration initiatives.
Support transition of legacy tooling data into Teamcenter-managed environments.
Maintain tooling libraries and standardized engineering data structures.

Global Collaboration

Work effectively with global engineering teams and stakeholders.
Collaborate across multiple regions, suppliers, and manufacturing facilities.
Present technical recommendations and project status updates to management and customers.

Qualifications

Education

Bachelor''s Degree in Mechanical Engineering or related discipline.

Experience

10+ years of experience in automotive BIW fixture and tooling design.
Minimum 3 years of engineering leadership or team management experience.
Experience supporting tooling development from concept through production launch.
Experience working with global engineering teams and suppliers.
Experience in CAD/PLM data migration projects preferred.
Automotive OEM manufacturing launch experience preferred.

Technical Skills

Required

Advanced Siemens NX expertise including:
3D Modeling
Assembly Design
Drafting
Kinematics
Strong Teamcenter knowledge including:
Structure Management
Workflows
Configuration Control
BIW fixture design and welding tooling expertise.

Knowledge of:

Spot Welding
MIG/MAG Welding
Laser Welding
Riveting
Clinching
Adhesive Joining
Supplier coordination and tooling buy-off experience.

Preferred

Ford Global Product Development System (GPDS/GDPS) experience.
Exposure to Ford Fixture Design and Evaluation System (FIDES).
Experience with standard component libraries and classification management.
Robotic EOAT and automation tooling expertise.
Leadership Soft Skills
Proven people leadership and team development capability.
Strong problem-solving and decision-making skills.
Excellent stakeholder management and conflict-resolution abilities.
Strong verbal and written communication skills.
Ability to work effectively in multicultural and global environments.