Staff 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 Staff Mechanical Engineer is a thought leader in the design and industrialization of major new content for GILLIG’s continuously evolving product line. The Staff Mechanical Engineer will have direct influence over vehicle, system, and component level design decisions providing thought leadership and working on broader organization projects, which requires understanding of the full mechanics of the bus and the wider business. 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 of Structures and Powertrain.

• 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.

• Limited travel may be required

• 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.)

• Typical start time is between 5:00 – 7:30AM (negotiable)

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.

ADDITIONAL QUALIFICATIONS

• Demonstrated experience in design, development, and optimization of vehicle structures, focusing on weight reduction, stiffness enhancement, and crash safety

• Ability to perform basic finite element analysis (FEA) to predict structural performance under various loading conditions (static and dynamic)

• 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 selection to meet target performance requirements

IN THIS ROLE YOU WILL

• Gather information regarding supplier components, existing GILLIG designs and technological advancements to rationalize and optimize design concepts

• Play a lead role in interpreting customer requirements, deploying actionable engineering requirements and evaluating possible requirement incompatibilities

• Deploy 2D and 3D CAD tools, fully self-managed in all operations, including decision making on new departmental practices, methods and standards

• Manage large assemblies and employ various other techniques such as developing & managing part families and facilitating importation of data into TeamCenter

• Use analytical tools to assess designs of self and others, including but not limited to, stress, vibration, thermal performance, and durability

• Create and maintain Bill of Materials (BOM), defining appropriate application of parts & assembly. Apply concepts of modular BOM structure and provide input on rule sets for proper configurator definition

• Provide significant support towards engineering programs, defining most of the technical schedules & deliveries as well as assisting with cost definition

• Provide engineering input for technical publications, such as service and driver manuals

• Collaborate and iterate designs with cross-functional partners such as electrical, controls and manufacturing engineers

SCOPE OF THE ROLE

• Autonomy: Ability to work independently with review at critical points and may direct the activities of others. Accountable for results that may impact the entire department

• Technically Minded: Serve as an expert in the field and key advisor. Provide, guide and use professional concepts in developing resolution to critical issues. Apply extensive knowledge of theories, practices and design matters. Lead the application of existing principles and guide development of new ideas

• Time Management: Work is completed at a highly accelerated pace due to familiarity with subject matter and execution experience

• Communication: Collaborate and teach up, down and across the organization to help raise the skills and knowledge of the GILLIG team. Create formal networks involving coordination among groups. Convey advanced information and persuade diverse stakeholders

• Complexity: Work on significant and unique issues where analysis of situations or data requires an evaluation of intangibles. Require conceptual thinking to understand advanced issues and implications. Exercise independent judgment in methods, techniques and evaluation criteria for obtaining results. Recognized internally as a subject matter expert

• 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

BASIC QUALIFICATIONS

• Bachelor or advanced degree in Mechanical Engineering

• Minimum 8 years of experience within the Engineering industry

• Experience in automotive and/or heavy-duty vehicle design required

• 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

• Experience in the direct design of components including Design for Manufacturing (DFM), Design for Service (DFS), and cost-efficiency (Value Engineering)

• Experience with “hands-on” troubleshooting, product assembly, prototyping, testing, and validation activities (on site and at remote locations)

• Working-level knowledge of electric motors, inverters, battery management systems (BMS), power electronics, and electric vehicle architecture

• A drive to stay current with the latest BEV and ICE technology and regulations

WORK ENVIRONMENT

• 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

• Limited travel may be required

• 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.)

• Typical start time is between 5:00 – 7:30AM (negotiable)

EXPECTED COMPENSATION

$75,000 - $275,000/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.

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.