MAR_125 - Vehicle DFMEA Engineer — Two-Wheeler Development

Location: Bangalore, India

Department: NPD

Experience: 4-8 Years

• Define functions, requirements, failure modes, effects, causes, and prevention/detection controls.
• Identify vehicle-level and interface-related risks across chassis, suspension, brakes, powertrain, battery, motor, electrical systems, wiring harness, body, and rider interfaces.
• Conduct DFMEA reviews with Design, Vehicle Integration, CAE, Testing, Manufacturing, Quality, Suppliers, Service, and Program teams.
• Drive risk-reduction actions, track closure, and escalate critical open items.
• Link DFMEA outputs with DVP&R, design reviews, test plans, PFMEA, Control Plans, and engineering change processes.
• Update DFMEA based on design changes, test results, prototype issues, manufacturing feedback, warranty concerns, and field failures.
• Support lessons learned, DFMEA standardization, and continuous improvement across vehicle programs.

• Strong knowledge of AIAG–VDA DFMEA methodology, including structure analysis, function analysis, failure analysis, Action Priority, and risk mitigation.
• Experience in two-wheeler vehicle development, vehicle integration, design engineering, testing, quality, or reliability engineering.
• Understanding of two-wheeler systems: frame, chassis, suspension, steering, brakes, tyres, powertrain, electrical architecture, body systems, and vehicle packaging.
• For EV programs: knowledge of battery pack, BMS, motor, controller, charger, wiring harness, high-voltage safety, and thermal management.
• Familiarity with APQP, PPAP, PFMEA, Control Plans, DVP&R, 8D, 5 Why, root-cause analysis, and engineering change management.
• Working knowledge of PLM/PDM, BOM, CAD release, and FMEA tools such as APIS IQ-FMEA, ReliaSoft XFMEA, or equivalent.
• Strong cross-functional communication, workshop facilitation, action tracking, and technical documentation skills.