The Safety Laboratories Department (SLD) is a 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 testing and provides engineering direction and support for the crash facilities.
Crash Test Engineering
Coordinate full-vehicle crash tests for Regulatory and Corporate Safety/Public Design Guideline requirements.
Interface with requesting engineers and witness authority to verify test objectives and requirements and ensure all aspects of testing requirements are being met.
Lead team of technicians with test mode impact point and vehicle alignment.
Coordinate photographic technicians and sensor supplier support timing/process.
Work with dummy lab personnel to ensure that proper procedures are being followed for dummy positioning or to meet the customer specific needs.
Record all dummy measurements using the Coordinate Measuring Machine (CMM) and software and generate Measurement Report for the customers.
Conduct quality assurance activities, reviewing test data, investigating and reporting data anomalies.
Complete post-test assessments and high-speed video review. Document vital observations pertinent to regulations and corporate requirements.
Generate final test report, including auto-processing and highlight process deviations when required. Provide written comments for observations and results from required engineering evaluations. Generate and compile data from various data sources to be included in final test report.
Complete post-test Regulatory and Design Requirement evaluations, including door open-ability, restraints retention, fuel system integrity, windshield retention and intrusion, etc. Communicate preliminary results to test requestors.
Crash Operations Engineering
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). Help with the use of specialized or unique equipment, tools and configurations.
Resolve operational issues and implement measures to prevent recurrence. Work closely with lab personnel (unit supervisor, technologists and technicians) to identify and implement actions to improve operational quality, cost and timing. Provide support for the function and configuration of test control software and automated data processing tools. Assist with the maintenance and monitoring of lab metrics.
Work closely with Crash program requesters, the Automotive Safety Office (ASO), and other Safety Lab Department (SLD) test engineers to support vehicle program testing. Help resolve test capability and performance concerns and assess data for anomalous behavior. When necessary, complete root-cause analysis, non-conformance communication and response plans; document as 5D's when appropriate.
Attend daily crash barrier scheduling meeting, provide input to scheduling and report out status/issues for individual tests.
Work with management and technician staff to deliver work schedule or recover from delays.
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
Ability to work afternoon shift 3:00pm-11:30pm weekdays
Highly organized; able to manage multiple long and short term projects effectively
Strong leadership skills for cross-functional cooperation and issue resolution
Ability to use Outlook, Word, Excel, and other MS Office applications
Excellent written and oral communication skills
Ability to work off shifts and weekends as necessary to support testing milestones
Recent experience in crash test and/or crash operations engineering
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
Working knowledge of SPROUT (test request manager), SPRITE Test Stand (DAS control), and Diadem (data post-processing)
Personal vehicle for travel to and from work location.
Unusual or Special Physical Requirements of Position (specify and provide % of time required)
Description of Work Environment (specify and provide % of time required)
Inside? Outside? Combination? Where?: Inside, office environment, test lab, 100)%
Extreme (hot/cold) temperatures involved: NA
Hazardous conditions - What are they?: Dynamic test cells, crash barrier facility.
Travel/transportation requirements: May require occasional local travel, 25%. Need personal vehicle to travel to and from work site.
Equipment and Machines Involved in Work Tasks (specify and provide % of time required)
Criticality of Attendance (specify and provide % of time required)
Overtime, regular days, off days: Monday through Friday 3:00PM to 11:30PM, 100% Very occasional need to arrive early or stay late dependent upon projects and interactions with parties globally.
Shift, 1st, 2nd, 3rd: Afternoon shift, training will be on day shift. Occasional need to work day shift weekdays dependent up on facility workload. Occasional need to work Saturday and/or Sunday dependent up on facility workload
Necessity for regular attendance: Critical
Urgency for punctuality: Critical
Work hours are normally 8 hours per day and 5 days per week, Monday-Friday. Regular attendance of scheduled hours is extremely important. Punctuality and regular attendance are necessary. Must have flexibility of work days to cover weekend testing requirements.
Other Essential Functions (List other essential functions here.)
Must demonstrate professional behavior at all times when dealing with customers, management and co-workers. Must have clear, concise and accurate communications skills in English, both verbal and written. Grooming and dress must be appropriate for the position and must not impose a safety risk to self or others. Must maintain a positive work atmosphere by behaving and communicating in a professional manner. Dependable personal transportation to work site is required.
Must complete and pass a pre-employment drug screen, health performance evaluation, and background check.