Design Release Engineer (DRE) - Overhead Systems

About the role

We're ALTEN Technology USA, an engineering company helping clients bring groundbreaking ideas to life-from advancing space exploration and life-saving medical devices to building autonomous electric vehicles. With 3,000+ experts across North America, we partner with leading companies in aerospace, medical devices, robotics, automotive, commercial vehicles, EVs, rail, and more.

As part of the global ALTEN Group-57,000+ engineers in 30 countries-we deliver across the entire product development cycle, from consulting to full project outsourcing.

When you join ALTEN Technology USA, you'll collaborate on some of the world's toughest engineering challenges, supported by mentorship, career growth opportunities, and comprehensive benefits. We take pride in fostering a culture where employees feel valued, supported, and inspired to grow.

Key Responsibilities & Tasks

• Lead end-to-end design release of Overhead Systems components (Headliner, Sun Visor, Grab Handle, Overhead Console, Interior Lighting, Microphones, Cameras) across Client vehicle programs.
• Own and manage all technical data across Client systems: 3D/2D CAD releases, GD&T drawings, PBOM/eBOM, piece numbers, and engineering documentation throughout the full execution phase.
• Drive supplier engagement through all APQP gates: design reviews, DFMEA development, tooling feasibility, APQP deliverable tracking, timing management, and cost/quality alignment.
• Build, own, and actively manage DVP&R plans; coordinate and validate test execution for durability, environmental, thermal, NVH, abuse, and safety requirements; track open items and drive closure with suppliers.
• Lead and participate in DFMEA development with suppliers; ensure DFMEA sign-off aligns with tooling release gates per Client APQP requirements.
• Support prototype builds (Mule, VP, PPAP, Launch) to resolve fit, finish, function, and integration issues; attend in-plant build events at supplier and assembly facilities as required.
• Manage tooling milestone gates (T1/T2/T3); coordinate tooling release sign-off, dimensional approval, CMM reviews, and PPAP/PSW submission per Client APQP gate requirements.
• Apply formal root cause analysis tools (5-Why, KT, Red X) to diagnose and permanently resolve design, material, and manufacturing issues; lead corrective action with suppliers.
• Manage engineering changes end-to-end: initiate, evaluate, and close CNs/ECNs in Teamcenter; assess cost, weight, and timing impact; coordinate cross-functional approval.
• Define part breakup, assembly sequence, and master sections for the Program of Record (POR); develop source packages including PBOM, eBOM, tech sheets, and DVP&R.
• Perform packaging, manufacturing, and assembly feasibility studies for OHS components; evaluate DFM/DFMA compliance and drive design optimization with suppliers.
• Support In/Out/Explo decision-making using standard decision matrices (quality, cost, timing, performance); synthesize program requirements including financial targets, weight budgets, and complexity with theme styling.
• Maintain issue logbooks; present top open issues and risk status to management weekly; lead crossfunctional actions to closure.
• Conduct benchmarking studies as required; identify cost reduction and value optimization opportunities throughout the program lifecycle.

Preferred Education

• Bachelor's degree in Mechanical Engineering, Automotive Engineering, or related field.

Preferred Experience Essential

• 8+ years of Product Design & Development experience in automotive Interior Trim and/or Lighting Components, with direct DRE executionphase experience on Overhead Systems (Headliner, Sun Visor, Grab Handle, Overhead Console, Interior Lighting, Microphones, Cameras).
• Expert proficiency in CAD tools (CATIA V5/V6 or NX/UG) for 3D design release, 2D drawing creation, GD&T application, and master section development.
• Expert-level proficiency in PLM/PDM systems (Teamcenter); full ownership of eBOM/PBOM structure, piece number management, and CN/ECN processing throughout execution phase.
• Deep knowledge of DFM/DFMA principles and DFMEA development; proven ability to lead DFMEA sign-off with suppliers aligned to Client APQP gate requirements.
• In-depth knowledge of automotive interior component manufacturing processes (injection molding, compression molding, plastic welding, foaming, vacuum forming, thermoforming); experience managing tooling milestones (T1/T2/T3), dimensional approval, and CMM reviews through to PPAP/PSW.
• Demonstrated ownership of DVP&R plans: build, track, and close test execution for durability, environmental, thermal, NVH, abuse, and safety requirements; experience with PBOM/eBOM management and full technical documentation suite.
• Ability to interpret feasibility criteria for styling and engineering integration; proficiency with formal root cause analysis tools (5-Why, KT, Red X) to drive permanent corrective actions.
• Proven leadership in resolving complex cross-functional design issues; ability to mentor junior engineers and act as technical authority for OHS system on program.
• Strong communication and presentation skills; ability to lead design reviews, escalate risks to senior management, and align cross-functional teams including Styling, Safety, Manufacturing, Purchasing, and Quality.
• Ability to manage full supplier lifecycle: technical reviews, APQP gate tracking, DFMEA, DVP&R coordination, tooling release, PPAP/PSW, and in-plant support for prototype builds and program launch.
• Expert-level knowledge in manufacturing and assembly feasibility, with demonstrated experience driving DFM optimization from concept through production ramp.

Desirable

• Work experience with International Tier 1 and OEMs.
• Extensive in-plant experience including tool tryouts (T1/T2/T3), prototype builds (Mule, VP, PPAP, Launch), assembly line support, and program launch activities at supplier and OEM facilities.

Language Requirements

• Essential: English Software skill requirement
• Knowledge in UG/NX & Team center.
• Knowledge in MS-Office or Google G-Suite.

Recommended Additional Skills

• Familiarity with Client -specific processes and milestones (SOP readiness reviews, Client APQP phases and gates, eVIEW/ePDM, Teamcenter authoring).
• Experience in the full sourcing process (In/Out/Explo, RFQ packages, supplier selection, SOR/SOW development) and knowledge of weight management and mass sign-off processes.

Additional information

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