Crash Test Safety Test Engineer

Crash Test Safety Test Engineer

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.

Position Duties:

• 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.

• 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

Highly organized; able to manage multiple long and short term projects effectively

Strong leadership skills for cross-functional cooperation and issue resolution

Strong MS Office suite and computer skills to create and publish test instructions, logs and reports.

Excellent written and oral communication skills

Ability to work off shifts and weekends as necessary to support testing milestones

Preferred:

• 1+ years of experience in a Crash Safety Testing environment.
• 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
• Applied understanding of Measurement Uncertainty, Equipment Calibration, Data Acquisition, Control Systems Fundamentals, SPC, QOS, FMEA, G8D and 6-Sigma skill set or certification
• Ability to develop business cases and presentations to upper management
• Demonstrated experience leading capital improvement projects ($100k minimum)
• Personal vehicle for travel to and from work location.

Other Qualities to look for:

• Motivated
• Self-starter
• Willing to help where needed
• Attention to details
• Calm under pressure
• Positive, Can-Do attitude
• Effective and professional communication skills
• Problem solving skills
• Good work ethics