Lead Handles Development Engineer

Role details

Location

United States

Start and end date

26 Oct 2026 – 03 Oct 2027

Indicative hourly rate

$42 – 45/hr

Respond by

20 Oct 2026

Skills

Design for Manufacturability, Working Model, Injection molding, Engineering, Failure Mode & Effects Analysis, Catia, Manufacturing processes, Six Sigma, Enovia, Microsoft Excel, Geometric Dimensioning & Tolerancing, Electronics, TeamcenterDesign for Manufacturability, Working Model, Injection molding, Engineering, Failure Mode & Effects Analysis, Catia, Manufacturing processes, Six Sigma, Enovia, Microsoft Excel, Geometric Dimensioning & Tolerancing, Electronics, Teamcenter

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Overview

Our client is seeking high‑caliber Lead Engineers to drive the end‑to‑end development of exterior and interior door handle systems across multiple current production vehicle programs. This role partners closely with the client's supplier base to re‑engineer handle mechanisms using existing architectures with new suppliers, delivering production‑ready solutions on an accelerated timeline.

Each Lead Engineer will own a specific handle architecture and its variants, serving as the primary technical point of contact from concept through production launch.

Key Responsibilities

• Lead supplier partners through an accelerated ("go‑fast") design‑to‑production development process for door handle opening systems
• Own overall technical delivery for assigned handle architectures, including exterior and interior handle mechanisms
• Manage suppliers through all development phases, ensuring parts are released for production tooling
• Ensure all tooled parts are validated and approved per PPAP requirements
• Drive program timing, milestone compliance, and deliverable readiness; proactively identify and resolve risks
• Communicate program status, issues, and recovery plans to the client's management and cross‑functional stakeholders

Essential Duties

• Collaborate closely with suppliers to develop robust, production‑ready designs
• Track development plans and delivery milestones to achieve scheduled PPAP timing
• Perform and lead design, CAD, and drawing reviews
• Coordinate and review analytical verification activities (simulation, calculations, tolerance stack‑ups, T&E)
• Ensure designs comply with engineering best practices, the client's standards, and system requirements (Health Charts / Checklists)
• Coordinate technical development activities, schedules, and resolution of engineering issues
• Integrate product, process, and lessons‑learned issues into DFMEA documentation
• Coordinate supplier validation testing and review test plans and reports
• Coordinate the client's internal vehicle‑level and subsystem validation testing
• Maintain regular communication with internal the client's teams and external suppliers
• Prepare interim and final project reports and technical presentations
• Release components for production (WERS) and support production issues (SREA, Alerts)
• Manage supplier design data within the client's systems (CAD models, drawings, CAE data)

Required Qualifications

• 10+ years of experience in mechanical mechanism development, preferably in latching systems, door handles, or exterior mechanisms
• Strong knowledge of engineering plastics and steels, including manufacturing processes such as injection molding, stamping, and casting
• Experience performing and/or leading tolerance analysis studies
• Proficiency with DFMEA and related quality tools, including:
• Boundary/Parameter Diagrams
• Requirements Decomposition Matrix (RDM)
• Interface Matrices
• DVP&R, DOE, SPC, statistical analysis
• Problem‑solving methodologies (5D, 8D, 6‑Panel, Six Sigma)
• Solid understanding of DFM/DFA and GD&T principles
• Experience reviewing and working in CATIA V5/V6
• Familiarity with Teamcenter / ENOVIA for CAD data management
• Strong written and verbal communication skills
• Proficiency with Microsoft Office (Excel, Word, PowerPoint)

Preferred Qualifications

• Experience with water management and sealing design
• Knowledge of greases and painted plastics
• Familiarity with embedded electronics such as microswitches and small wiring harnesses
• Experience with tolerance analysis tools such as C‑Tol, 3DCS, Enventive, or VSA
• Experience with CAE tools such as ADAMS, Working Model, CATIA FEA, HyperMesh, or similar

Requirements

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Skills

• Design for Manufacturability — Intermediate
• Working Model — Intermediate
• Injection molding — Intermediate
• Engineering — Intermediate
• Failure Mode & Effects Analysis — Intermediate
• Catia — Intermediate
• Manufacturing processes — Intermediate
• Six Sigma — Intermediate
• Enovia — Intermediate
• Microsoft Excel — Intermediate
• Geometric Dimensioning & Tolerancing — Intermediate
• Electronics — Intermediate
• Teamcenter — Intermediate

Languages

• English — Professional working proficiency