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The Senior Lead Engineer – Design will lead end-to-end product and platform development for air disc brake calipers and their peripheral systems, including carriers, adjuster mechanisms, tappets, sealing systems, slide mechanisms, wheel hubs, slack adjusters, and related mechanical and mechatronic braking systems. The ideal candidate brings substantial design engineering experience within the heavy-duty transportation industry, with demonstrated product knowledge of air disc brake technology. This role carries full accountability for design direction, technical decision-making, and successful delivery of braking system programs from concept through production launch.About The Role
Senior Lead Engineer - Design | Heavy Duty Transportation R&D - Brakes
Reporting to: Sr. Project Lead | Location: Bangalore, Full Time
Qualification: B.E./B.Tech./M.Tech. in Mechanical Engineering | Experience: 10-12 Years
Position Overview
The Senior Lead Engineer - Design role within the Heavy Duty Transportation R&D team is accountable for leading end-to-end product and platform development across air disc brake calipers and its peripheral systems like carriers, adjuster mechanisms, tappets, sealing systems, slide mechanisms, wheel hubs, slack adjusters, and related mechanical or mechatronic braking systems. The role will define product architecture, establish technical roadmaps, and guide projects from concept through validation and production launch. The incumbent will provide technical leadership to project teams, own design quality and technical risk, and ensure delivery against performance, cost, timing, manufacturability, and customer requirements.
The role requires close collaboration with global business units, product management, simulation, validation, manufacturing, quality, procurement, suppliers, and customers. The Senior Lead Engineer will drive innovative and cost-effective solutions through NPD, VAVE, DFM/DFA, design reviews, DFMEA, root-cause analysis, benchmarking, and continuous improvement.
Mandatory Skills
- 10-12 years of progressive experience in product design and development of air disc brakes, brake calipers, wheel-end systems, or closely related heavy-duty commercial-vehicle braking products.
- Demonstrated experience leading end-to-end NPD and VAVE projects, including requirements, concept development, detailed design, prototype development, verification/validation, design release, and production launch.
- Strong technical expertise in 3D CAD and engineering drawings, GD&T, tolerance stack-up, design calculations, DFM/DFA, and the design of castings, machined components, stampings, fasteners, sealing interfaces, and precision brake assemblies.
- Proven ability to lead design reviews, DFMEA, DVP&margin-top:0cm;">Proven ability to lead design reviews, DFMEA, DVP&margin-top:0cm;">Proven ability to lead design reviews, DFMEA, DVP&R, technical-risk mitigation, prototype builds, testing, field/production-failure resolution, and robust corrective actions.
- Experience in FEA for structural analysis and test corelation
- Hands-on experience with prototype development, lab testing, durability validation and design correlation activities
Desired Skills
- Practical understanding of FEA for structural of brake components, interpretation of simulation results, correlation with test data, and design optimization.
- Experience in air disc brake reverse engineering and understanding of calipers, carriers, adjuster mechanisms, tappets, sealing, fasteners, slide mechanisms, thermal/environmental management, brake-pad and rotor interfaces, and air chamber integration.
- Familiarity with Stage Gate Design Review, APQP, DFMEA, PFMEA, PPAP, DVP&R, and applicable commercial-vehicle braking requirements.
- Experience collaborating with global engineering teams, suppliers, manufacturing, quality, procurement, validation, and customer stakeholders.
- Working knowledge of project planning, resource coordination, schedule/cost control, stakeholder communication, and delivery governance.
- Strong coaching, mentoring, presentation, collaboration, problem-solving, and ownership capabilities; willingness to travel within or outside India as required.
- Understanding of mechatronic-system integration involving brake components, sensors, actuators, and controls.
Key Responsibilities
- Provide technical leadership for multiple or complex product-development and VAVE projects, from requirements definition through production launch.
- Define brake product or system architecture, engineering requirements, technical roadmap, design strategy, and validation approach.
- Lead brake concept generation, feasibility assessment, trade-off studies, concept selection, design calculations, tolerance stack-ups, material selection, sealing strategy, and detailed design.
- Own technical decisions, design quality, engineering deliverables, technical risks, mitigation plans, and design-release readiness.
- Lead brake design reviews, DFMEA, DVP&R/validation planning, prototype builds, dynamometer, laboratory and vehicle testing, correlation, and closure of design issues.
- Guide the design of calipers, carriers, adjuster mechanisms, tappets, slide systems, seals, fasteners, castings, machined components, assemblies, and applicable mechatronic interfaces.
- Drive DFM/DFA, modularization, automation readiness, cost optimization, supplier strategy, and scalable manufacturing solutions.
- Lead VAVE, brake product improvement, warranty/field-failure resolution, production-issue resolution, and corrective/preventive actions using structured RCA methods.
- Benchmark competitive brake products, manage reverse-engineering activities, assess relevant technology and intellectual-property landscapes, and translate Voice of Customer needs into engineering requirements.
- Coordinate cross-functional execution and monitor engineering scope, resources, schedule, cost, deliverable quality, risks, and recovery actions.
- Mentor and technically develop engineers; establish engineering best practices, checklists, standards, and reusable design knowledge.
- Support customer and supplier technical discussions and present design recommendations, project status, and technical evidence to leadership.
Opportunities for Growth
• Lead end-to-end product and platform development for a broad heavy-duty braking and wheel-end product portfolio.
• Deepen expertise in brake product architecture, validation strategy, VAVE, advanced manufacturing, friction/tribology, thermal management, and mechatronic integration.
• Gain global exposure through collaboration with business units, customers, suppliers, and cross-functional engineering teams.
• Build technical-leadership capability through mentoring, engineering governance, and ownership of complex technical decisions.
Required Qualifications
• B.E./B.Tech./M.Tech. in Mechanical Engineering.
• 10-12 years of progressive product-design and development experience in heavy-duty air disc brakes, commercial-vehicle braking, wheel-end systems, or closely related industrial products.
• Advanced proficiency in SolidWorks and/or NX, engineering drawings, GD&T, tolerance stack-up, casting and machining drawings, fastener and sealing interfaces, and ANSI/ASME drawing practices.
• Clear and concise verbal, written, and presentation skills for technical and leadership audiences.
Following receipt of a conditional offer of employment, candidates will be required to complete additional job-related screening processes as permitted or required by applicable law.
