Mechanical Development Engineer - Gearbox Job at BorgWarner (San Luis Potosí)

Job Description

A Mechanical Development Engineer (MDE) for Differential, Gears & Shafts is responsible for the design, development and release of components that are used in conjunction with each other within an assembly to meet the overall performance requirements of a product. The MDE works within the eDrive Engineering organization in collaboration with CAD Designers and CAE (Computer – Aided Engineering) Engineers. The MDE must be capable of completing work requests from the Project Team Members to meet the defined program performance requirements and timing. In this role, the MDE is responsible for requesting design and analysis work from the CAD and/or CAE team members while working simultaneously with Manufacturing, Purchasing, and suppliers to receive input and to address technical issues in preparation for production launch, and during production to support cost reductions and robust improvements.

Job Responsibility

Develop differential, gears and shafts components to meet performance, cost, and manufacturability targets
Collaborates with system integration, NVH, and durability teams to optimize driveline performance
Support New Business Opportunity (NBO) initiatives by designing and developing mechanical systems and subsystems, including integrated drive modules (iDMs) and fully assembled eMotors, with a focus on components such as differential, gears and shafts
Support Value Analysis/Value Engineering (VA/VE) initiatives within application projects by identifying opportunities to optimize cost, enhance performance, and improve manufacturability
Demonstrate thorough knowledge of component drawing requirements for differential, gears, and shafts, including dimensional tolerances, application of GD&T, and utilization in stack-up calculations to ensure design integrity and assembly compatibility
Conduct engineering analyses and calculations on components and sub‑systems, and present technical rationale to program teams to support design decisions and ensure compliance with performance requirements
Issue CAE requests and provide technical direction for system and component analyses to support design validation and optimization
Create and maintain component and sub-system Design Failure Mode and Effects Analyses (DFMEAs) and utilize them to define and manage Special Characteristics that ensure product reliability and compliance with program requirements
Create design work orders and provide direction to CAD resources to develop product designs
review, approve, and release engineering drawings to support program requirements
Utilize Siemens Teamcenter to manage engineering drawings, maintain Bill of Materials (BOM) structures, and oversee 3D model development to ensure accuracy, consistency, and compliance with program standards
Create Advanced Design Verification Plan and Report (ADVP&R) to validate the component performance, and issue laboratory work orders to direct technicians in conducting component testing
Analyse mechanical components for wear and durability to ensure compliance with performance and reliability requirements
Prepare test reports documenting outcomes of component and system validation activities
Support vehicle-level integration and troubleshooting during development and launch
Support tooling development and process validation
Act as technical liaison with Purchasing, suppliers, and Supplier Development Engineers for new component projects involving differential, gears, and shafts
Establish technical requirements for supplier selection and contribute to the decision-making process
Willingness and ability to travel locally to manufacturing sites, with a primary focus on gaining hands-on knowledge of the assembly line and providing support for component design and production-related concerns as needed
Review and approve internal and external engineering change requests to ensure compliance with design standards, quality requirements, and program objectives
Provide technical support for differential, gears & shafts by addressing component issues identified during validation testing or warranty analysis, ensuring timely resolution and design improvements to maintain product reliability and customer satisfaction
Identify and propose cost‑reduction opportunities within differential, gears & shaft component families to optimize value while maintaining performance and quality standards
Support the global engineering organization by sharing technical knowledge, lessons learned, and best practices to drive consistency, efficiency, and continuous improvement across programs
Promote component re‑use by leveraging knowledge of the global component family to optimize designs, reduce cost, and ensure consistency across programs

Requirements

Minimum of a bachelor’s degree in Mechanical Engineering or related field
Over 5 years of engineering experience driving innovation and efficiency in the automotive sector and global manufacturing environments with High proficiency in English
Proven hands-on experience with EV (Electric Vehicles) and ICE (Internal Combustion Engines) powertrain systems, driving innovation across transmission and electric drive modules
Background in powertrain systems, with specific expertise in differential, gears and shafts with demonstrated experience in development, or integration regarded as an asset
Demonstrated success in designing, developing, and launching advanced powertrain systems from concept to production
Gear Design: Involute geometry, tooth contact analysis, load distribution, and efficiency optimization
Shaft Design: Torsional strength, bending fatigue, critical speed analysis, and spline design
Differential Systems: Knowledge of open, limited slip, and electronic differentials
torque biasing and load sharing
Materials Engineering: Metallurgy of steels and alloys, surface hardening, coatings, and tribology
Testing & Validation: Bench testing, rig testing, and vehicle-level validation for durability and performance
Manufacturing Processes: Forging, machining, grinding, heat treatment, and quality control methods
DVP&R planning and execution for differential, gears and shaft components
Experience in powertrain, driveline and/or 4WD systems is preferred
Intermediate proficiency in 2D/3D CAD modelling and technical drawing using NX primarily and CATIA as preferred
Experience and/or training in APQP, DFM/DFA
Understanding of various testing & validation processes
Fatigue testing, NVH testing, Thermal testing, environmental testing, Endurance testing is a plus
Teamcenter knowledge
proficient in Microsoft Office (Outlook, Word, Excel, PowerPoint)

Nice to have

Understanding of key manufacturing processes related to differential, gears and shafts
Strong interpersonal skills and a collaborative mindset, with proven ability to work effectively in team environments
Work with electromagnetic, thermal, mechanical, and manufacturing teams
Interface with suppliers for differential, gears and shaft components sourcing and validation
Support system integration into eDrive assemblies
Team-oriented with excellent organizational abilities, including prioritization, multitasking, handling multiple projects simultaneously and deadline management
Service-oriented mindset with a proactive approach
Self- directed/motivated and capable of working independently with minimal supervision
Requires professional verbal and written communication skills along with the capability to manage complex technical details with precision
Excellent drive for results with the ability to coordinate projects from start to completion
Experience and/or training in Root Cause Analysis is preferred

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Mechanical Development Engineer - Gearbox

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