Job Description
Role Overview
The Exterior Lead will be responsible for end-to-end design, development, and validation of exterior components, with strong focus on bumper systems. The role requires managing full product development lifecycle, leading cross-functional teams, and ensuring delivery of robust, cost-effective, and manufacturable designs aligned with OEM requirements.
Key Responsibilities
1. Design & Development
• Lead design and development of front & rear bumper systems, fascia, grilles, air dams, energy absorbers, carriers, and related exterior trims.
• Create/modify 3D CAD models and 2D drawings using CATIA V5/V6/ UGNX or equivalent tools.
• Define engineering specifications, DFMEA, DVP, and design guidelines.
• Ensure manufacturability (DFM/DFA) for injection moulding, blow moulding, extrusion, painting, and assembly processes.
2. Project Leadership
• Lead cross-functional teams (Styling, CAE, Manufacturing, Purchase, Quality) through product development milestones.
• Manage design gateways, feasibility reviews, and engineering change management (ECM/ECR).
• Drive timing plans, deliverables, BOM creation, and release processes.
3. Validation & Testing
• Coordinate physical and virtual validation: crash requirements, pedestrian protection, durability, environmental tests, fit & finish, gap/flush analysis.
• Work closely with CAE teams for simulations (NVH, crash, impact, thermal).
• Support prototype build, tooling development, and PPAP/APQP activities.
4. Supplier & Customer Interface
• Work with Tier-1/Tier-2 suppliers on feasibility, tooling, material selection, and cost optimization.
• Communicate design status/updates to OEM clients and internal stakeholders.
• Ensure alignment with global standards, regulations, and homologation needs.
Required Skills & Experience
• 7–12+ years in automotive exterior design and development with major experience in bumper systems.
• Strong hands-on skills in CATIA/UGNX surface modelling (Class A/B/C), solid modelling, and packaging.
• Deep understanding of plastics design, tooling, tolerances, GD&T, fastening strategies, and assembly systems.
• Knowledge of material properties (PP, PC+ABS, TPO, ASA, lightweight materials).
• Familiarity with global OEM processes (PPAP, APQP, DFMEA, DVP&R).
• Excellent problem-solving, cost optimization, and stakeholder management skills.
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