DRE Brakes and Pedals

SEGULA Technologies; Auburn Hills (MI); On-site; USD 90,000 - 140,000; Full time

Job summary

Segula Technologies in Michigan seeks a Brake System & Pedals Design Engineer responsible for end-to-end design, development, validation, and release of tunable brake system components and pedal assemblies across current and new vehicle programs.

You will lead design, sizing, regulatory compliance, supplier integration, CAE coordination, DVP&R, and field support, coordinating with Tier-1 suppliers and internal QA teams.

Responsibilities

• Lead the design, packaging, and release of brake tunable components (Boosters, TMC, Calipers, Drums, Discs, Hoses, Tubes) and Pedal assemblies (Brake and Accelerator Pedals).
• Perform brake system sizing, kinematic calculations, and ensure homologation/regulatory compliance across target global markets.
• Study packaging, serviceability, cost implications, and component interdependencies within the vehicle architecture.
• Develop requirement matrices, write RFQs, conduct technical reviews, and manage supplier selection.
• Monitor supplier development schedules, tooling/fixture/gauge progress, and process development to fit vehicle assembly requirements.
• Oversee process error-proofing, line inspection methods, Control Plans, PFMEAs, and PPAP approvals with Tier-1 suppliers.
• Define durability and functional objectives for brake and pedal components, and manage the DVP&R.
• Guide CAE analysis teams to evaluate fatigue life cycle, dynamic stiffness, pedal feel, and NVH characteristics.
• Coordinate physical testing and sample validation (DV/PV) to meet program quality gate KPIs.
• Provide engineering support during pre-series test builds and mass production launches at assembly plants.
• Investigate and drive root-cause analysis (8D, 5-Why, DFSS) for early vehicle warranty and field-return concerns alongside quality and service teams.
• Identify and execute Value Optimization / VAVE initiatives for component cost and weight reduction.

Job description

Position Overview

The Brake System & Pedals DRE is responsible for the end-to-end engineering design, development, validation, and release of tunable brake system components, pedal assemblies, and interface hardware. This role covers components such as Brake Boosters, Tandem Master Cylinders (TMC), Calipers, Drum Brakes, Brake Discs/Rotors, Brake Lines/Hoses, Parking Brake mechanisms, and Brake & Accelerator Pedal assemblies across current and new vehicle programs.

Key Responsibilities

Component Design & Development

• Component Engineering: Lead the design, packaging, and release of brake tunable components (Boosters, TMC, Calipers, Drums, Discs, Hoses, Tubes) and Pedal assemblies (Brake and Accelerator Pedals).

• System Sizing & Compliance: Perform brake system sizing, kinematic calculations, and ensure homologation/regulatory compliance across target global markets.

• Architecture Integration: Study packaging, serviceability, cost implications, and component interdependencies within the vehicle architecture.

Supplier & Program Management

• Technical Sourcing: Develop requirement matrices, write Requests for Quotations (RFQs), conduct technical reviews, and manage supplier selection.

• Timeline Tracking: Monitor supplier development schedules, tooling/fixture/gauge progress, and process development to fit vehicle assembly requirements.

• Supplier Quality Oversight: Oversee process error-proofing, line inspection methods, Control Plans, PFMEAs, and PPAP approvals with Tier-1 suppliers.

Validation, CAE & Attribute Balancing

• Test & Verification Planning: Define durability and functional objectives for brake and pedal components, and manage the Design Verification Plan & Report (DVP&R).

• Simulation Integration: Guide CAE analysis teams to evaluate fatigue life cycle, dynamic stiffness, pedal feel, and NVH characteristics.

• Sample Validation: Coordinate physical testing and sample validation (DV/PV) to meet program quality gate KPIs.

Assembly Plant & Field Quality Support

• Plant Build Support: Provide engineering support during pre-series test builds and mass production launches at assembly plants.

• Root-Cause Analysis: Investigate and drive root-cause analysis (8D, 5-Why, DFSS) for early vehicle warranty and field-return concerns alongside quality and service teams.

• Cost & Weight Optimization: Identify and execute Value Optimization / VAVE initiatives for component cost and weight reduction.