Senior Hardware Engineer - ECU Mechanical DFMEA Analysis

Description

The Ideal Candidate:

New Electronic Control Unit (ECU) designs used in automotive applications continue to be an area of growth in the global automotive market. Our team is looking for a creative and highly energetic ECU Hardware Analysis Engineer who can perform mechanical DFMEA analysis of ECU mechanical elements and assist in developing our internal analysis approach and procedures for inhouse electronics designed ECUs. This work will be in support of the overall Safety and Reliability Case development for ECUs used within the Software Defined Vehicle (SDV) electrical architecture technologies that are critical in achieving GM's Vision of Zero Crashes, Zero Emissions, and Zero Congestion.

Mechanical DFMEA analysis plays a critical role in ensuring the robustness, durability, and environmental resilience of ECUs used in automotive applications. This activity focuses on identifying mechanical risks early in development and driving design improvements that protect ECU performance throughout its lifecycle. The ideal candidate will have previous experience with mechanical DFMEA at the ECU level, drive innovation, facilitate effective communication, and inspire enthusiasm within the team. We expect you to demonstrate leadership qualities, actively champion change, possess keen business intuition, and strategically address systemic challenges. You should also exhibit high learning agility, the ability to navigate ambiguity and complexity, and a commitment to pushing the boundaries of innovation while challenging the status quo.

The Role:

Safety is truly in your hands, as your passion for safe mobility will be key in ensuring the safe and reliable operation of our inhouse developed ECUs for our latest vehicle architecture. In this role you are expected to have a high level of technical proficiency to perform various ECU and sub-component mechanical analysis tasks that supports various SDV ECUs, and provide mentoring to more junior engineers within the team. This role will function in the capacity of performing the required mechanical analysis within an ECU design responsible organization where work products will be delivered to the Mechanical Design and Quality Teams within our organization to meet mechanical design best practices and reliability expectations of various ECUs. This role will interface across various GM engineering disciplines as well as external engineering entities to obtain needed information for the required analysis work.

What You'll Do:

• Lead mechanical DFMEA activities for ECU mechanical elements-including housing/enclosure, seals/O-rings, connectors, PCB mechanical interfaces, mounting features, and thermal management components-following AIAG-VDA DFMEA methodology.
• Analyze mechanical functions, requirements, and interfaces to identify potential failure modes related to vibration, thermal cycling, ingress protection, mechanical fatigue, and environmental exposure.
• Facilitate cross-functional DFMEA reviews with design, materials, manufacturing, quality, and validation teams to ensure accurate risk assessment and alignment with automotive safety and reliability requirements.
• Develop and maintain DFMEA documentation, ensuring compliance with AIAG-VDA standards and seamless integration with APQP (Advanced Product Quality Planning) and design release processes.
• Recommend and drive design improvements, working with mechanical and electrical design teams to mitigate risks through enhanced sealing, structural reinforcement, tolerance optimization, fastener strategy, and connector/mechanical interface robustness.
• Support validation planning by linking DFMEA findings to DVP&R (Design Verification Plan and Report) activities such as vibration, shock, sealing/IP testing, thermal cycling, and environmental durability assessments.
• Contribute to lessons learned and continuous improvement, applying industry standards and prior field data to strengthen future ECU mechanical designs and reduce warranty risk.
• Integrate Mechanical DFMEA with Electrical Component/Circuit level DFMEA(s) in GM's FMEA Integration Tool and ensure linkages to higher level System and Sub-Systems DFMEAs are in-place for traceability measures.
• Perform read-across of Mechanical DFMEA design lessons learned, best practices and failure mitigation measures across all in-house designed ECUs.
• Develop new and/or revise existing mechanical requirements for ECU CTRS (Component Technical Requirements Specification) needed for improved product designs.
• Actively lead, participate and contribute in ECU HW Change Control and Mechanical Design Peer Review forums.
• Domestic and/or international travel as required (minimal, 10% max).

• 5+ years engineering experience in product development with ECUs or ECU mechanical DFMEA analysis.
• Bachelor of Science degree in Mechanical Engineering, Electrical Engineering, Aerospace Engineering, Physics or another related Engineering degree.
• Previous mechanical design, analysis, development and/or validation experience with automotive ECUs
• Demonstrated leadership and project management of complex technical projects.
• Ability to provide technical leadership and mentorship to diverse global teams.

• 8+ years engineering experience in product development with ECUs or ECU mechanical DFMEA analysis.
• Master of Science in Engineering or related field
• Familiarity with mechanical design and reliability standards, analysis tools and techniques:
  • Mechanical CAD Design & Mark-up: Teamcenter, NX CAD and Teamcenter Visual Mockup
  • Mechanical PCB Design & Solderability: IPC-6012DA, IPC-A-610 Class 3, IPC-2221A, IPC-4101C, J-STD-001
  • Environmental & Mechanical Testing: GMW-3172, ISO-16750, UL-94/UL-796, AEC-Q100/Q200
  • Other: ISO-26262 in relation to mechanical safety mechanisms that support Functional Safety, electronics sub-component mechanical design integration within ECUs as it relates to mechanical reliability performance and failure mechanisms.
  • DFMEA Analysis/Documentation: Plato-e1ns or other analysis/documentation tool used for Mechanical DFMEA
• Machine learning, simulation methods and data acquisition.