Senior Engineer I, Customer Engineering (Mechanical)

GILLIG LLC is the largest and most dependable manufacturer of Heavy-Duty Transit Buses in North America. Our customers are in all 50 states, and include cities, counties, transit districts, universities and major private fleet operators. We are headquartered in Livermore, CA.

Our engineering organization is comprised of three primary departments: Current Product Engineering (CPE), New Product Engineering (NPE) and, Product Validation. There are two groups within CPE, Customer Engineering and Sustaining Engineering.

The mission of the Customer Engineering group is to define robust fleet-specific customization required for each of our customers’ operational needs.  Customer Engineering has technical responsibility from the initial bid through vehicle delivery; encompassing bid team support, translation of requested features into parts and functionality, design & release of components/installations, validation support, and implementation into production.

This Engineering position is responsible for engineering design, problem resolution and other engineering duties in support of the design and manufacturing of sub-systems.  This person will have direct influence at sub-system level to optimize the piece parts and sub-systems for one of the following areas: Driver Interior or Powertrain.  This Senior Engineer I for Driver Interiors and Powertrain reports to the Engineering Supervisor, but may also get direction/guidance from senior engineers.  This is a direct, full-time position with GILLIG.

You will collaborate with internal and external partners to interpret customer requirements, supply chain capabilities, manufacturing capabilities and business needs. You will contribute to complex designs at the sub-system and vehicle level, devising optimal product solutions in concert with electrical and product validation peers.

For Driver Interior:

• The Driver’s Interior area is central to the operation of the bus and is designed unique to each customer’s order. This area of responsibility is from the front wheel wells to the windshield and is where driver ergonomics, endless option content, and regulatory/compliance all converge to create a unique engineering and configuration management challenge
• Design work in the Driver’s Interior includes both design of GILLIG components as well as integration supplier components
• The dominant areas of design and integration include Driver Seating, Driver Dash Layout & Overhead Controls, Driver Partitions/Barriers, Fare Collection, and Wheel Well Equipment Stowage
• Familiarity with Driver Ergonomics and/or ADA compliance standards is highly desirable

 For Powertrain:

• The Powertrain team is responsible for the integration of the drivetrain of the bus as well as any ancillary or supplemental systems which include but not limited to the fuel system, powertrain cooling, air intake, aftertreatment and fire detection/suppression. This spans across all powertrain offerings from diesel, CNG, hybrid and electric propulsion, each with their own unique challenge
• Design work in this area of the bus is highly driven by integration of supplier components requiring strict adherence to supplier or regulatory requirements as applicable while meeting specific customer requirements
• Familiarity with internal combustion engines or electric powertrain systems is highly desirable

• Communicate subsystem level design/idea to internal/external customers
• Evaluate customer product requirements and develop product designs to meet customer needs
• Interpret customer requirements, and map requirements onto existing designs when possible, and/or develop new designs when needed
• Optimize designs via analytical, numerical and/or empirical assessments. Make mechanical, thermal and electrical models/analysis to ensure product requirements are met
• Produce and/or evaluate possible design solutions to improve cost, quality, delivery and performance on specialized knowledge of engineering applications together with possible involvement of other functional engineers and/or customer/supplier personnel
• Direct CAD designer to complete 3D models and drawings as necessary
• Release drawings accordingly to support production cost estimation and prototype quotes
• Review CAD models and drawings at the component and sub-system level to ensure their integrity
• Use CAD modeling software to create components, assemblies, and engineering drawings for manufacturing
• Conceptualize appropriate mechanical & electrical design including design for manufacture and assembly
• Document final design upon the successful development of component and simple sub-system, which includes releasing the final technical specification, related design calculation, and the design manual or guideline
• Create and maintain Bill of Materials (BOM) along with all project documentation
• Design and document solutions, within the scope of concepts, for components and modules, taking project guidelines (e.g. safety, quality, cost, weight and dates) into consideration
• Detail mechanical & electrical design including design for manufacture and assembly
• Advise stakeholders on the technical issues that affect the product design, production cycle-time & cost
• Analyze assignments and determine engineering specifications which must be fulfilled for problems or projects
• Support production ramp & ongoing/continuous product/process improvement
• Perform and coordinate laboratory testing of prototypes for sub system characterization
• Work with the test engineer(s) to create DVP&R, execute the defined test plan and review the test results/reports
• Conduct field testing and provide preliminary evaluations
• Develop and maintain the technical specification for desired performance at the sub-system level
• Prioritize assigned tasks to maintain schedule
• Work independently on assigned sub-system tasks with some guidance required from senior engineers on sub-system level tasks
• Work productively with other engineers, designers, technicians, sales representatives, installers, and project managers so the project is delivered on schedule and on budget
• Provide technical design support to sales, product engineering, manufacturing, and quality organizations
• Provide technical guidance to junior engineers at component and sub-system level
• Organize design review with the manufacturing engineer team as well as project review with the management team to make sure product development completion on time
• Support purchasing, field service and other internal customers as required
• Lead or support prototype order and procurement
• Operate in a team environment and provide input to design solution during the design development phase
• Apply knowledge of company products, policies and practices to provide economies through standardization of parts and products.
• Apply lean principles in designs and processes
• Area of expertise at the sub-system level
• Develop individual analytical skills, knowledge regarding tools as well as methods to analyze a given design problem and develop a good understanding of design risk factors. (Pre req for DFMEA line above)
• Ensure model and drawing documentation is accurate and complete
• Exhibit insight and mechanical/electrical design sense to develop and meet design requirements with product designs that are manufacturable, cost-efficient, reliable, and better than the competition.
• Hands-on troubleshooting of vehicle systems
• Lead Root Cause Analysis
• Make sound decisions after careful deliberation of the alternatives and will revisit prior decisions as justified by new information
• Release designs that are cost effective, manufacturable, serviceable, meet all performance objectives, and meet customer requirements
• Support design decisions with detailed analyses
• Validate designs virtually with FEA and CFD along with real world validation using test rigs, dynamometer, etc.

• BS in Mechanical Engineering or equivalent
• Minimum 5 years of engineering experience
• Understanding of Heavy-Duty Transit Bus Duty Cycle
• Understanding of and ability to read and produce mechanical drawings
• Understanding and application of structural Finite Element Analysis (FEA) for components and weldments
• Understanding and application of Geometric Dimensioning & Tolerancing (GD&T)
• Understanding of automotive mechanical systems and functions and ability to read and produce mechanical drawings
• Understanding of typical manufacturing tolerances associated with sheet metal and machined parts
• Application of sound electrical design fundamentals
• Working knowledge in electrical power distribution including AC and DC systems
• In-depth knowledge of the electrical load calculation and circuit protection
• Experienced with high voltage system design and necessary safety guidelines
• Experienced with low voltage harness design
• Experienced in generating harnesses and electrical schematic using CAD software
• Familiarity with automotive components such as circuit breakers, relays, and wiring, etc.
• Familiarity with automotive industry standards such as SAE, NFPA, FMVSS, etc.
• Familiarity with manufacturing processes and environment
• Ability to diagnose and troubleshoot automotive electrical systems

• Ability to lift up to 25 lbs.
• Working environment is primarily indoors (office and production environment), however, at times job may require time spent outdoors
• Regularly required to sit, stand and walk and occasionally kneel or squat
• May be required to work overtime based on business needs
• Limited travel may be required
• Typical start time 6:00AM (negotiable)

Salary:  $97,129 - $121,411

We are interested in every qualified candidate who is eligible to work in the United States. However, we are not able to sponsor work visa’s now or in the future.

After 130 years, GILLIG holds strong to its family values and focus on its employees and customers. Our motivated and dedicated employees have a passion for quality and customer satisfaction. We are committed to building buses that connect communities, eliminate congestion, and contribute to a greener environment. Our Company pride is exemplified by the thoughtful design and quality craftsmanship present in every GILLIG bus. GILLIG’s steadfast focus on quality and unwavering commitment to exceptional customer service sets us apart from our competition.  

In compliance with the Drug-Free Workplace Act of 1988, GILLIG has a longstanding commitment to provide a safe, quality-oriented and productive work environment consistent with the standards in which the company operates. Drug abuse poses a threat to the health and safety of GILLIG employees and to the security of the company's equipment and facilities. For these reasons, GILLIG is committed to the elimination of drug and alcohol use and abuse in the workplace. All applicants must pass a drug test before beginning work.

GILLIG offers an excellent compensation and benefits package including 100% company-paid premiums for medical, dental and vision for employees and their families. Other benefits include a unique 401k profit-sharing plan.

GILLIG is an equal employment opportunity and affirmative action employer.

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