Dimensional Engineering Lead

We are seeking an experienced Dimensional Engineering professional to support automotive product development, manufacturing engineering, vehicle launch, and quality improvement activities for global OEM programs.

The role is responsible for dimensional feasibility, GD&T and variation management, tolerance optimization, measurement system deployment, dimensional validation, and launch support throughout the vehicle development lifecycle, including SOP and post-launch stabilization activities.

The successful candidate will work closely with Product Design, Perceived Quality (PQ), Manufacturing Engineering, Supplier Quality, Metrology, Plant Launch, Production, and OEM customer teams to ensure robust dimensional performance, achievement of vehicle quality targets, and successful product launches.

Dimensional Engineering & Product Development

• Perform dimensional feasibility analysis during concept, design, development, and industrialization phases.
• Conduct Digital Mock-Up (DMU) reviews to identify dimensional risks, package constraints, assembly concerns, and manufacturability issues.
• Support design convergence by evaluating dimensional performance against engineering requirements, vehicle targets, and manufacturing capability.
• Develop and maintain dimensional control strategies and dimensional control plans for vehicle systems and assemblies.
• Define and drive achievement of vehicle-level dimensional quality targets including Gap & Flush, Flushness, Feature Relationship, and other Perceived Quality (PQ) requirements.
• Collaborate with Product Design, PQ, BIW, and GA Process Engineering teams to improve dimensional robustness and manufacturing feasibility.

GD&T, Datum Strategy & Tolerance Management

• Develop and implement robust GD&T schemes, datum structures, and locating strategies for BIW panels, BIW sub-assemblies, closure systems, GA trim parts, and vehicle integration interfaces.
• Review engineering drawings, CAD models, and technical specifications for dimensional compliance and manufacturability.
• Define functional dimensioning requirements aligned with product functionality, assembly requirements, and measurement strategies.
• Conduct 1D tolerance stack-up analysis using RSS (Root Sum Square) and Worst-Case methodologies.
• Perform tolerance optimization studies and Cost vs Tolerance trade-off evaluations balancing quality, manufacturability, process capability, and cost.

Measurement Systems, Fixtures & Tooling

• Define dimensional validation strategies and technical requirements for dimensional checking fixtures, attribute gauges, General Assembly fixtures, BIW fixtures, E-Cube systems, CMMs, and optical measurement systems.
• Support fixture concept development, supplier evaluations, procurement activities, installation, commissioning, and final buy-offs.
• Lead measurement system validation activities including fixture correlation, Gauge R&R, MSA, and capability assessments.
• Collaborate with metrology teams and suppliers to ensure measurement systems are robust and aligned with dimensional control requirements.

Vehicle Build, Launch Support & Process Capability

• Lead dimensional prove-out activities during prototype, pilot, pre-production, SOP, and post-launch (SOP + 90 Days) phases.
• Monitor dimensional performance against PIST targets, dimensional quality objectives, and BIW & GA Gap & Flush requirements.
• Drive dimensional issue resolution through structured root cause analysis, corrective actions, and production readiness assessments.
• Analyze dimensional data and evaluate process capability using Cp, Cpk, Pp, and Ppk methodologies.
• Perform variation analysis, tolerance optimization, and derogation assessments based on actual build and production data.
• Support supplier dimensional quality reviews, APQP/PPAP activities, dimensional sign-offs, and launch readiness assessments.
• Develop dimensional dashboards, reports, and trend analyses to support continuous improvement and data-driven decision-making.

• Bachelors Degree in Engineering in (Mechanical/Production /Automobile)
• Certifications in GD&T, Dimensional Engineering, Metrology, Tolerance Analysis, and Six Sigma preferred.
• Strong understanding of automotive product development, manufacturing processes of Body Shop & General Assembly (GA), and quality systems.

Dimensional Engineering & Product Development

• Dimensional Feasibility Analysis
• Digital Mock-Up (DMU)
• Design Convergence
• Vehicle Dimensional Integration
• Perceived Quality (Gap & Flush) Management
• Dimensional Control Planning & Risk Assessment

GD&T & Variation Management

• GD&T (ASME Y14.5 / ISO GPS)
• Datum Scheme & Locating Strategy Development
• Functional Dimensioning
• 1D/3D Tolerance Stack-Up Analysis (RSS, Worst-Case & Monte Carlo Simulation)
• Dimensional Variation Management
• Cost vs Tolerance Optimization

BIW & General Assembly

• BIW Panel & Sub-Assembly Dimensional Engineering
• BIW Clamping Plans & Fixture Locating Concepts
• Closure Systems & GA Trim Integration
• Vehicle Build Validation

Metrology & Measurement Systems

• CMM Measurement & Data Interpretation
• E-Cube Systems
• Dimensional Checking Fixtures & Gauges
• MSA / Gauge R&R
• Fixture Buy-Off, Correlation & Validation Activities

Statistical & Quality Tools

• Process Capability Analysis (Cp, Cpk, Pp, Ppk)
• Root Cause Analysis
• APQP, PPAP, FMEA & Control Plans

Software & Digital Tools

• CATIA V5 / 3DEXPERIENCE
• Teamcenter / PLM Systems
• 3DCS, VisVSA or equivalent variation analysis tools
• Microsoft Excel, PowerPoint & Power BI

• Proven experience in GD&T implementation, datum strategy development, locating scheme definition, dimensional feasibility reviews, tolerance stack-up analysis, process capability assessment, vehicle launch support, and dimensional issue resolution.
• Worked at least 3 new car development from early design to post-SOP stabilization.
• Experience supporting global OEM vehicle programs from concept through production.
• Experience with BIW, Closures, Interiors, Exteriors, or Vehicle Integration systems.
• Experience in supplier dimensional quality management.
• Experience in prototype, pilot, pre-production, SOP, and launch support activities.
• International onsite/customer-facing experience is highly desirable.

• 5–8+ years of experience in Automotive Dimensional Engineering, Manufacturing Engineering, Vehicle Integration, or Quality Engineering.