Senior Mechanical Engineer - Structures and Suspension

As the leading transit bus manufacturer in the United States, GILLIG buses play a critical role in the environmental and social initiatives in communities across our nation.  GILLIG is on the forefront in the transition to zero-emission vehicles and has an unmatched reputation in the industry for quality, reliability, durability, service, and support.  From initial design through final assembly, each GILLIG bus is designed and built in Livermore, CA. 

WHY GILLIG

• Leader in environmentally friendly mobility solutions including battery electric, hybrid electric, near-zero CNG and clean diesel transit buses
• Renowned for its inclusive team/family-oriented culture
• Stable, successful, and growing organization – a Bay Area business for over 132 years!
• Flexible schedules (*depending on project needs)
• Excellent compensation including company paid medical premiums, generous retirement plan and other comprehensive benefits

DEPARTMENT OVERVIEW

GILLIG Engineering is responsible for the development, customization, and configuration of GILLIG’s clean technology heavy-duty transit buses.  We are committed to developing the most reliable buses that connect communities, eliminates congestion, and contributes to a greener environment.  Our engineers are engaged in designing, analyzing, testing, launching, and problem solving across a wide range of technical areas. 

Mechanical Engineering is responsible for designing, developing, and optimizing mechanical systems and components, such as chassis, HVAC, interior layout, and powertrain integration to ensure safety, durability, and performance. They collaborate with cross-functional teams to meet regulatory standards, troubleshoot issues during production, and ensure cost-effective and efficient designs tailored to the needs of heavy-duty transit buses.

ABOUT THE ROLE

The Senior Mechanical Engineer is focused on the design and industrialization of content for GILLIG’s continuously evolving product line. The Senior Mechanical Engineer will have influence over complex vehicles, systems, and component level designs. Duties involve engineering assistance, problem resolution, mechanical design, BOM development, application research & other engineering duties in support of the manufacturing of heavy-duty transit buses. This person will have direct influence in the design of components and assemblies as well as mentoring other engineers within the engineering teams. This is a direct, full-time position with GILLIG.

This is a hands-on, on-site role at our Livermore, CA plant and reports to the Manager – Powertrain & Structures but may also receive direction and guidance from senior engineers.

TECHNICAL FOCUS

Structures & Suspension

The GILLIG bus consists of many welded, bolted, and riveted joints that make up the primary structural elements of the bus. Fluent knowledge of sheet metal design from component to assembly, including steel, stainless steel, and aluminum fabrications, extrusions, and castings is a typical daily demand.  Along with the structural aspect of the bus, the vehicle’s suspension, steering, braking, and pneumatic systems are integral to this group. This position requires the ability to review customer specifications & requirements and deliver chassis & body structure designs as well as suspension, steering, and pneumatic brake systems that meet these needs. The Structures team has consistently been where engineering mechanics, thermo-fluids, and Design for Manufacturing (DFM) all collide.

IN THIS ROLE YOU WILL

• Create and maintain Bills of Materials (BOM), defining appropriate application of parts & assembly; providing input on modular BOM structure to maintain and improve configuration efficiency
• Gather information regarding supplier components, existing GILLIG designs and technological advancements to rationalize and optimize design concepts
• Perform design trade-offs and optimization to devise robust, manufacturable, and maintainable design concepts
• Use 2D and 3D CAD tools to create, review & release vehicle components and assemblies
• Use analytical tools to assess your designs and others, including but not limited to stress, vibration, thermal performance, and durability
• Gain a mastery of both Customer & Design REI releases, including significant involvement in BOM structuring, Change Control, Production Change Order (PCO), and Engineered Production Change
• Support designs throughout the entire lifecycle, including development, production launch, variant designs & customization, and field support
• Provide expert input working with the test engineer(s) to create DVP&R, execute the defined test plan and review the test results/reports
• Provide technical input to technical publications
• Collaborate and iterate designs with cross-functional partners such as electrical, controls, manufacturing engineers, as well as production personnel
• Operate in a primary role, proposing solutions to more senior engineers or management for evaluation

• Autonomy: Ability to work independently with review at critical points
• Technically Minded: Apply industry practices and standards (NFPA, NEC, APTA, etc.) and provide input and advice to other staff members on industry practices and standards. Exhibit advanced wide-ranging experience, using in-depth professional knowledge, acumen, concepts and company objectives to develop, resolve complex models and procedures
• Time Management: Work productively to deliver projects on schedule and on budge
• Communication: Collaborate and teach up, down and across the organization to help raise the skills and knowledge of the GILLIG team. Adapt style to differing audiences and adept at persuasion on complex subjects
• Complexity: Responsible for a certain set of commodities or design elements within the team. Work on problems of diverse scope where analysis of information requires evaluation of multiple factors. Devise solutions based on limited information and precedent and adapt existing approaches to resolve issues. Use engineering principles, judgment, and interpretation to select the right course of action
• Quality & Standards: Model, drawing, and other technical documentation is accurate and complete. Released designs are cost effective, manufacturable, serviceable, meet all performance objectives, & meet customer requirements

• Bachelor or advanced degree in Mechanical Engineering
• Minimum 5 years of experience within the Engineering industry
• Automotive, commercial and/or heavy-duty vehicle design familiarity. Direct experience a plus
• Fluent with BOM, documentation control, and revision/version management. Experience with a configure-to-order product and modular BOM management a plus
• Fluency in CAD software such as NX, CREO, or SolidWorks
• Demonstrated working knowledge of GD&T and drawing creation
• Experience working with major component suppliers, engineering service suppliers, testing suppliers and product validation engineers
• Fluent in the direct design of components including Design for Manufacturing (DFM), Design for Service (DFS), and cost-efficiency (Value Engineering)
• Highly-skilled in “hands-on” troubleshooting, product assembly, prototyping, testing, and validation activities (on site and at remote locations)
• Demonstrated experience in design, development, and optimization of vehicle structures, focusing on weight reduction, stiffness enhancement, and crash safety
• Ability to perform moderate to complex finite element analysis (FEA) to predict structural performance under various loading conditions (static and dynamic). Understanding of fatigue analysis a plus
• Prior experience developing suspension kinematics and compliance models
• Exposure to utilization of simulations to predict ride and handling performance
• Working knowledge of suspension geometry and component parameters selections to meet target performance requirements\

• Ability to lift 25 lbs.
• Prolonged periods of sitting/standing at a desk and working on a computer
• Regularly required to sit, stand, and walk and occasionally kneel or squat
• The ideal candidate must be able to complete all physical requirements of the job with or without a reasonable accommodation.
• Must be able to navigate manufacturing environment, comfortable around heavy machinery, tools, etc.
• Must be able to wear Personal Protective Equipment, (i.e. safety glasses, bump caps, hearing protection, etc.)
• Less than 10% travel required
• Standard start time: 6:00 am (negotiable)

EXPECTED COMPENSATION

$75,000 - $163,570/annual salary + premium benefits  

Pay offered may vary depending on multiple individualized factors, including market location, job classification, job-related knowledge, skills, and experience. The total compensation package for this position may also include other elements dependent on the position offered. Details of participation in these benefit plans will be provided if a candidate receives an offer of employment.

Other Duties

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.

GILLIG is committed to providing equal opportunities to all employees and applicants for employment. We are committed to creating an inclusive and diverse workplace that values and respects the unique talents, experiences, and perspectives of our employees and the people we serve. As an equal opportunity employer, we do not discriminate on the basis of race, color, religion, sex, national origin, age, disability, genetic information, sexual orientation, pregnancy, gender identity or any other characteristic protected by law.

GILLIG is an equal employment opportunity and affirmative action employer.