Senior Engineer I, Sustaining (Electrical)

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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.

The Senior Engineer I position is responsible for engineering design, problem resolution and other engineering duties in support of the design as well as manufacturing of sub-systems.  The mission of the Sustaining Engineering team is to develop new option content, cost and performance improvements to the current product as well as drive resolution of technical Supply Chain, Production and Field issues.  Individuals will have direct influence at sub-system level to optimize the piece parts and sub-systems.  The Senior Engineer I position reports to the Engineering Supervisor but may also get direction/guidance from senior engineers. This is a direct, full-time position with GILLIG.

• Emphasis on providing robust, service-friendly, and cost-conscious electrical designs for vehicle low voltage (12/24VDC) and high-voltage (600VDC, 240/480VAC) systems
• Experienced troubleshooting capabilities that efficiently drive to root cause and ability to identify & implement permanent corrective actions
• Familiarity with vehicle and/or industrial control systems

• Communicate sub-system level design/ideas to internal/external customers
• Evaluate and interpret customer product requirements
• Develop product designs to meet customer needs
• Map requirements onto existing designs and/or develop new designs as needed
• Optimize designs via analytical, numerical and/or empirical assessments
• Ensure product designs are met by creating mechanical, thermal, and electrical model/analysis
• Produce and/or evaluate design solutions that improve cost, quality, delivery, and performance
• Direct CAD designer to complete 3D models and drawings as necessary
• Release drawings to support production, cost estimation and prototype quotes
• Review CAD models/drawings at the component, sub-system, and 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 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, 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 system level 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
• Ability to 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 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 mentorship/oversight to junior engineers at system level
• Organize design review with the manufacturing engineering team as well as project review with the management team to ensure product development completion is 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 system level
• Complete the initial concept DFMEA and continually update it throughout the life of the development
• Develops individual analytical skills and is also knowledgeable about the best tools/methods to analyze a given design problem as well as develop a solid understanding of design risk factors (Pre req for DFMEA line above)
• Model and drawing documentation are accurate/complete
• Hands-on troubleshooting of vehicle systems
• Lead Root Cause Analysis
• Released designs are cost effective, manufacturable, serviceable, and meet all performance objectives as well as customer requirements
• Supports design decisions with detailed analyses
• Validate designs virtually with FEA and CFD along with real world validation using test rigs, dynamometer, etc.
• Lead FMEA

• BS in Electrical Engineering or equivalent discipline required
• Minimum 5 years of engineering experience
• Understanding of:
  • Heavy-Duty Transit Bus Duty Cycle
  • Ability to read and produce mechanical drawings
  • Application of structural Finite Element Analysis (FEA) for components and weldments
  • Application of Geometric Dimensioning & Tolerancing (GD&T)
  • Automotive mechanical systems and functions
  • Ability to read and produce mechanical drawings
  • Typical manufacturing tolerances associated with sheet metal/machined parts
  • Application sound electrical design fundamentals
• Detailed knowledge and application of industry practices and standards (NFPA, NEC, APTA, etc.)
• Working knowledge in electrical power distribution including AC and DC systems
• In-depth knowledge of the electrical load calculation and circuit protection
• Exhibits insight and mechanical/electrical design sense to develop/meet design requirements with product designs that are manufacturable, cost-efficient, reliable, and better than the competition
• Experienced with high voltage system design and necessary safety guidelines as well as low voltage harness design
• Generating harnesses and electrical schematic using CAD software
• Familiarity with automotive components such as circuit breakers, relays, and wiring, etc.
• Understanding of 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 25 lbs.
• Regularly required to sit, stand, and walk and occasionally kneel or squat
• Limited travel may be required
• Typical start time is 6:00am (negotiable)

Salary:  $101,431 - $126,789

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.