Product Design Engineer

Job description:

Company and Position Background

Are you a visionary Product Design Engineer ready to shape the next generation of mobility lighting? For over 60 years, TYC has been a global leader, and now, our brand-new Wixom, MI facility is blazing a new trail as our first development and manufacturing hub outside of Asia. This isn't just a job; it's an opportunity to build, innovate, and lead from the ground up.

Company Culture Snapshot

TYCA Michigan is a close-knit, dynamic team where all ideas and voices are celebrated. Communication is valued with daily morning check-ins and regular staff meetings. Camaraderie and collaboration are prioritized through monthly team building events, regular lunch outings, and open-door meeting policies.

A positive impact on the community and employee’s lives is achieved through Corporate Social Responsibility (CSR) activities sponsored by TYCA and safety-first policies.

At TYCA Michigan, you'll find a close-knit, dynamic team where every idea is celebrated. We foster a culture of collaboration, continuous improvement, and open dialogue.

Job Summary:

The Product Design Engineer is responsible for but not limited to the following activities:

Design and Development:

• Interface daily with customer Studio and Engineering team
• Attend and present in customer Mtgs
• Perform Lamp Section Layout Packaging study and review with Asian PD Engr to decide direction
• Review 3D CAD and 2D Dwgs (in CATIA V5) and provide feedback to Asian PD Engr
• Review/update engineering documents: RFQ Tech PPT, DFMEA, DVPR, BOM, Design Open Issue List, Option Matrix, Milestone Review PPT, Design Check Sheets, Issue analysis summary, ECR etc
• Lead and conduct benchmarking activities in US for competitive products, create reports
• Lead prototype & mockup activities, evaluate and test to prove design concepts (if needed)
• Lead Design for Manufacturing (DFM) activities and assure implementing DFM into all designs
• Lead design review activities with Asian & US team, ensuring all open items are closed and solutions are implemented into design on time, document evidence.
• Follow APQP process: together with Asian team to release 3D & 2D to customer, suppliers and internal team at DR2, DR3, Pre-TKO and TKO milestones, organize PD data in SharePoint folders

Leverage support of back-office engineering team:

• Interface daily with Asia-based primary engineering team providing detailed work plans, communications, CAD files, and synthesize results for presentation to customer.
• Synthesize outputs from customer meetings and provide structured input to engineering team to direct their ongoing efforts.
• Translate, synthesize and summarize the results of engineering team’s work for presentation to customer and upper management.
• Work closely with Tooling/Molding & Manufacturing Engr to ensure early and full incorporation of Design for Manufacturing (DFM) into all designs

Testing and Validation:

• Stay updated on relevant automotive lighting standards and regulations (e.g., ECE, CCC, FMVSS 108, SAE standards).
• Stay updated on customer testing specs, work with customer to get DVPR approved
• Work with EE and validation Engr to detail validation test plans per DVPR, ensure product performance and compliance with Regulation, Industry standards and customer specs
• Support Validation Engr on DV Failure study: analyze test data, failure samples, identify root cause and implement solutions, retest until test pass.

Collaboration and Cross-Functional Teams:

• Work/collaborate closely with Optics, Electronics, CAE in Asia (daily base) to ensure design performance and feasibility
• Work/collaborate closely with Tooling, Molding, Manufacturing and Quality Engr in USA to ensure Design for Manufacturing
• Work/collaborate closely with supply chain specialists to ensure design cost and supplier resilience meet target
• Manage multiple projects simultaneously, ensuring timely delivery of project milestones.
• Prepare and present technical reports and design reviews to stakeholders.
• Be capable to clearly speak/describe/communicate any issues in front of a large group.
• Possess strong organizational skills managing engineering data and understand customer’s product development process/milestones.

On-Site Resident Engineer:

• Use pre-existing CAD skills in Siemens NX or Catia v5 to download, open, share and analyze vehicle and lamp design and data. Develop concept studies and sketches/study files to primary engineering team in Asia, provide guidance to their detail work.
• Attend/Lead PDT meetings, Design Studio meetings, vehicle build events and other customer meetings during the development, validation and production of the vehicle lighting system.
• Conduct/Support testing and evaluation of the lighting systems at customer (e.g. Proving Ground) facilities.
• Lead all Design Review presentations as required by customer (e.g. Peer Reviews). Also, participate in review meetings, as requested by customer.
• Support the vehicle launch at the Assembly Plant(s). Expectation is to be present for all build events. Attend plant launch meetings.
• Complete all customer-required documentation for changes and ongoing issues (e.g. EWO’s and PRTS’)

While this position is not a people-leading role, leadership and teamwork skills are desired in all candidates. The future is open for all employees to grow into leadership positions within the organization. TYCA supports employee development and career planning to elevate you to the next level.

While this position is not a people-leading role, leadership and teamwork skills are desired in all candidates. The future is open for all employees to grow into leadership positions within the organization.

TYC supports employee development and career planning to elevate you to the next level.

Employee Profile

The ideal candidate would embody:

• Self-starter who is not afraid to roll their sleeves up to contribute their own creativity, passion, & vision
• Strong communication and teamwork skills to integrate with the entire TYCA team
• Not afraid to tackle challenges head-on and eager for growth opportunities
• Enjoys contributing to a dynamic team on rewarding projects
• Approaches tasks with an organized and systematic mindset to maintain timing
• Excellent interpersonal and communication skills with internal and external stakeholders
• Resourceful approach to problem-solving and root cause analysis

Qualifications Required

Experience:

• Previous hands on experience in automotive exterior lighting products design & development, with a minimum of 5 years experience
• Previous experience with overseas design collaboration
• Have managed/engineered successful lighting programs from sourcing through start of production.
• Competent in Catia V5 or Siemens NX 3D CAD for design of automotive exterior lighting products. Able to learn another 3D CAD tool quickly with appropriate training (if needed)
• Previous experience with engineering and cost of automotive exterior lighting components: plastic injection molding, die casting, LED PCBA, Driver, wire harness, Standard parts etc., implemented design for cost, design for manufacturing in whole APQP cycle
• Working understanding of geometrical optics, optical systems, electronics components, thermal, condensation and vibration CAE used in automotive exterior lighting

Education:

• BS Engineering degree. Preferred Mechanical or Industrial engineering or equivalent experience

Desired qualifications:

• Self-directed worker able to internalize company’s best interests and balance with customer requests and find win-win solutions in a wide range of situations with minimal oversight and direction
• Able to communicate even bad or challenging information orally and in writing succinctly and clearly while maintaining composure and seeking win-win
• Mandarin Chinese language skills a strong plus
• Flexible team player willing to do what it takes to get the job done and satisfy the customer while maintaining company’s best interests
• Strong, competent English communicator, prefer English as first/native language. If not, have worked at least 1 year in work environment with English as primary communication language. English competency to be tested if not native

Job Type: Full-time

Benefits:

• 401(k)
• 401(k) matching
• Dental insurance
• Health insurance
• Life insurance
• Paid time off
• Vision insurance

Experience:

• Automotive Lighting: 5 years (Required)

Ability to Commute:

• Wixom, MI 48393 (Required)

Ability to Relocate:

• Wixom, MI 48393: Relocate before starting work (Required)
• Work Location: In person