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Senior/Staff Engineer - Friction Material Design

Akebono Brake Corporation seeks a Senior/Staff Engineer – Friction Materials Design in Farmington Hills, Michigan to perform the following:  Plan, design, and determine optimal conditions for the manufacture of friction materials for brakes in cars and trucks, utilizing knowledge of CAE, ABAQUS CAE, MATLAB, Polymath, C++, Minitab, R, Visual Basic, Prolink controls, statistical process controls, and DMAIC techniques. Review final project quotes for customer presentations, evaluate budget and project timelines, and negotiate with customers regarding technical requirements, specifications and validations. Review and coordinate experiments designed to investigate effects of temperature, pressure and time on the performance of brake pads and utilize the following statistical analysis techniques to optimize processing friction materials: ANOVA analysis, variance analysis, control charts, multi-variate regression modeling, capability analysis, distribution diagrams, multi-variate statistics and optimization techniques. Coordinate with quality manufacturing department to improve process flow and reduce waste utilizing Lean manufacturing knowledge. Review and interpret chemical, mechanical and physical test results for brake manufacture and investigate causes of variation in production lines utilizing interrelationship diagraph, affinity diagrams, and prioritization matrix, control charts, multi-variate regression modeling, and capability analysis.  Create formulation tables for friction materials and improve production process for brakes through investigating root cause process variations utilizing the following:  NGT techniques, FMEA, scatter plots, Pareto analysis, Forced Field analysis, and value stream mapping.  Review dynamometer for  friction materials performance. Mentor and train personnel on statistical data analysis tools, best practices and solutions.  Must have a Master of Science Degree in Industrial and Systems Engineering, Mechanical Engineering or foreign equivalent, and 2 years’ experience. Qualifying experience must be as an Engineer or substantially similar position performing the following:  Plan, design, and determine optimal conditions for the manufacture of friction materials for brakes in cars and trucks, utilizing knowledge of CAE, ABAQUS CAE, MATLAB, Polymath, C++, Minitab, R, Visual Basic, Prolink controls, statistical process controls, and DMAIC techniques; design experiments to investigate effects of temperature, pressure and time on the performance of brake pads and utilize the following statistical analysis techniques to optimize processing friction materials: ANOVA analysis, variance analysis, control charts, multi-variate regression modeling, capability analysis, distribution diagrams, multi-variate statistics and optimization techniques;  create formulation tables for friction materials and improve production process for brakes through investigating root cause process variations utilizing the following:  NGT techniques, FMEA, scatter plots, Pareto analysis, Forced Field analysis, and value stream mapping; and interpret chemical, mechanical and physical test results for brake manufacture and investigate causes of variation in production lines utilizing interrelationship diagraph, affinity diagrams, and prioritization matrix, control charts, multi-variate regression modeling, and capability analysis.

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