Lear Corporation
Website:
lear.com
Job details:
Position Title: Lead Engineer- DFMEA
Department: Engineering (Product Integrity & Technology)
Reports To: DFMT & DFMEA Manager
Location: Bhosari, Pune
Role Summary:
The DFMEA Engineer / DFMT–DFMEA Moderator leads structured technical risk analysis activities through both Design Failure Mode & Effects Analysis (DFMEA) and Design for Manufacturing & Tolerancing (DFMT) methodologies. This role ensures that product designs are robust, manufacturable, and compliant with customer and industry standards. The moderator aligns cross‑functional teams, drives data‑based decision‑making, and ensures seamless linkage between design intent, risk assessment, and manufacturing feasibility.
Key Responsibilities
- Lead, prepare, and moderate DFMEA sessions with cross‑functional teams
- Ensure DFMEA reviews follow AIAG/VDA or company-specific standards.
- Drive identification of potential failure modes, effects, causes, and controls.
- Ensure clarity, completeness, and traceability of DFMEA elements.
- Evaluate design concepts, interfaces, and requirements to identify potential risks.
- Track and verify implementation of recommended actions to reduce risk priority numbers.
- Maintain DFMEA documentation in APIS IQ.
- Ensure compliance with industry standards (AIAG/VDA FMEA Handbook, IATF 16949).
- Manage version control and audit readiness of DFMEA documents.
- Serve as a key interface between design engineering, quality, and manufacturing teams.
- Support customer technical reviews and respond to customer DFMEA‑related queries.
- Leverage lessons learned and warranty/field data to enhance DFMEA robustness.
- Lead and moderate DFMT (Design for Manufacturability & Testing) with Design, Manufacturing Engineering, Quality.
- Ensure DFMT discussions follow structured guidelines for manufacturability
- Ensure manufacturability risks are identified early and mitigation actions are initiated by Engineering.
Key Qualifications
Education
- Bachelor’s or Master’s degree in Mechanical, Automotive, Electrical/Electronics, or related engineering field. Electronics preferable.
Experience
- 5–10 years of experience in DFMEA, design engineering, quality engineering, or product development.
- Hands-on experience with DFMEA tools: APIS, IQ-FMEA or Equivalent.
Technical Skills
- Strong understanding of product design principles and engineering fundamentals.
- Knowledge of AIAG & VDA aligned FMEA methodology (mandatory).
- Understanding of DVP&R, boundary diagrams, P-diagrams, DRBFM preferred.
- Familiarity with IATF 16949 / ISO 9001.
Soft Skills
- Strong facilitation and moderation skills.
- Ability to lead cross-functional technical discussions.
- Excellent communication, analytical, and documentation abilities.
- High attention to detail and structured-thinking approach.
Key Performance Indicators (KPIs)
- Quality and completeness of DFMEA documents.
- On-time DFMEA submissions aligned with project milestones.
- Reduction of high‑risk items (Action Priority / RPN).
- Cross‑functional engagement and participation rates.
- Audit compliance (internal, external, customer).
- On-time completion of DFMT reviews aligned to project gates.
- Reduction of manufacturability issues in prototype and early builds.
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