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Sr Design Engineer Lighting
Auto req ID: 4980BR
Title: Sr Design Engineer Lighting
Job Function: Engineering
State and City: Wisconsin, Wauwatosa
Company: Harley-Davidson Motor Company
Full or Part-Time: Full-Time
Shift: Shift 1

Job Summary
At Harley-Davidson Motor Company we do much more than just build motorcycles; we fulfill dreams of personal freedom. We are customer led in all we do, and we believe and invest in our people and our communities. Harley-Davidson believes that its people are the only real long-term competitive advantage and their energy and commitment is what has made us successful since 1903.

This Engineering position will be held accountable for delivering the following:

• Develop and deliver lighting component/systems that follows the H-D lighting strategy/roadmap and supports product life cycle plans across the H-D vehicle portfolio, including modularity/complexity strategies.

• Develop and maintain project specific product requirements documentation for new lighting both within H-D and between H-D and suppliers to enable world class designs.

• Lead technical relationship with the lighting component suppliers through weekly design reviews and/or visits.

• Manage development and risk through robust FMEA and DVP&R creation at component and system levels.

• Resolve technical issues for performance and integration between lighting components and the vehicle

• Resolve technical issues between styling and lighting supplier, cost targets, and timing restraints.

• Review and approve supplier DFMEA’s, PFMEA’s, test plans, test reports, PPAP’s and controls plans to ensure lighting system meets or exceeds H-D requirements.

• Evaluate and report performance of lighting components subjectively and objectively via conspicuity and night ride evaluations.

• Responsibilities include using engineering tools such as CAD models and drawings, predictive analysis such as FEA and conventional engineering calculations such as bolted joint analysis and tolerance stacks with documentation supporting the analysis

• Document best practices or lessons learned using standardized processes and tools: Benchmarking; design & simulation guidelines; DFMEA & DVP&R templates; drawing templates; critical path planning templates and general knowledge management that enable new product & current product development success.

• Support lighting group through relentless continuous improvement, professional & technical growth, peer collaboration, and team focused participation.

Education Required
This position requires a Bachelor’s Degree in Mechanical Engineering, other engineering degrees will be considered. A Master’s Degree is a plus.

Experience Required
This position requires a minimum of five (5) years of relevant experience. In addition they will have demonstrated the following:

Mechanical/Electrical System & Component Development & Delivery

• Experienced with design and delivery of complex supplier led designs.

• Skilled at managing design with cross-functional stakeholder requirements.

• Demonstrated success in completing designs that meet their quality, cost, timing, weight and performance objectives.

• Experience with design and delivery of lighting systems/components is a plus

• Experience with circuit design, circuit analysis, and/or electrical testing is a plus Project Management

• Understands project management tools and principles (in topics such as requirements, scheduling, risk mitigation, budget, and metrics) through training and experience.

• Efficiently executes prescribed project management processes with minimal coaching.

• Experience leading complex supplier led designs.

• Engineering drawing creation, authorizations, and changes

• Experience creating and authorizing component drawings.

• Experience creating 2D and 3D sketches in order to facilitate design direction to stakeholders.

• Familiarity with Pro-E and the PLM system is a strongly preferred. Target Setting and Product

Requirements Document (PRD) Creation

• Experience setting robust product targets for performance.

• Ability to lead vehicle night ride evaluations for setting headlamp performance targets Engineering Calculations

• Demonstrates an advanced understanding of engineering calculations and regularly applies them to design problems and references calculations in reports and analysis guides.

• Can quickly recall and demonstrate engineering calculations during design reviews to provide decision ready information.

Design for Manufacturing (DFM)

• Experience designing for most of the manufacturing processes and materials used at H-D, such as complex injection molding, vacuum metalizing, spray and flow coating, painting, aluminum die casting, vibration welding, hot plate welding, glue joints, etc.

• Experience designing for the manufacturing processes and materials such as forgings, sheet metal stamping, forming and deep-drawing, extrusion, machining, chrome plating, etc. is a plus.

• Knowledgeable about the specific needs of each process and how to optimize designs and drawings to minimize cost and manufacturing difficulty.

Design for Fit & Finish

• Familiar with geometric dimensioning & tolerancing (GD&T) and datum structure development.

• Experience with creating clean drawing datum structures and dimensioning schemes.

• Experience with conducting multiple part/system tolerance stacks using both straight and RSS stack up methods.

• Understands general inspection methods and how GD&T callouts can communicate functionality, feature importance and/or drive cost Design for Assembly (DFA)

• Experience developing designs that are easy and efficient to assemble correctly, difficult to assemble incorrectly, and accommodate the needs of the assembly operator and specific assembly line or station.


• Experience with conducting design reviews based on failure modes (DRBFM).

• Has led/facilitated DFMEA/DVP&R design reviews.

• Capable of helping others identify and resolve gaps in completeness and accuracy & how to engage appropriate stakeholders for DFMEA input.

Product Verification & Validation

• Familiarity with creating component and system level test plans

• Experience reviewing component and system level test results

Supplemental Information
At Harley-Davidson it is not just what degree you have or what you know you must also exhibit and demonstrate our valued behaviors in everything that you do:

• Be accountable

• Model Integrity

• Value Individuality and Diversity

• Inspire Teamwork

• Encourage Creativity

Direct Reports:
Travel Required: 0-10%