Description

We are seeking a highly experienced Lead Engineer in Dimensional Variation Analysis (DVA) to drive dimensional quality and manufacturing robustness across vehicle development programmes. This role focuses on GD and T tolerance stack-up analysis and variation control while leading cross-functional teams and managing programme deliverables.

The ideal candidate will bring strong expertise in dimensional engineering tools automotive systems and program leadership to ensure fit function and aesthetic requirements are consistently achieved.

Responsibilities

Dimensional Engineering and Analysis

- Lead DVA activities for vehicle systems and sub-systems
- Perform and review tolerance stack-up analysis across 1D 2D and 3D environments
- Apply GD and T standards (ASME or ISO) across product designs
- Conduct feasibility studies and optimise tolerances to meet functional and aesthetic requirements
- Lead root cause analysis of dimensional issues and drive corrective actions

Software and Tools

- Use advanced dimensional analysis tools such as 3DCS VisVSA CETOL or equivalents
- Perform simulation-based validation for dimensional performance
- Support digital validation processes within product development cycles

Program Management

- Own dimensional deliverables across vehicle programmes
- Manage timelines risks and stakeholder expectations
- Define and track KPIs for dimensional quality and variation control
- Collaborate with global engineering teams to meet programme milestones

Cross-Functional Collaboration





- Work closely with design manufacturing quality and supplier teams
- Ensure alignment between design intent and manufacturing capability
- Drive standardisation and best practices in dimensional engineering

Leadership and Capability Development

- Lead and mentor a team of engineers
- Drive continuous improvement initiatives in dimensional analysis practices
- Support innovation in modelling simulation and validation approaches

Qualifications

Education

- Bachelors or masters degree in mechanical or automotive engineering or a related field

Experience

- Minimum 7 years of experience in dimensional engineering or variation analysis
- Experience in automotive OEM or Tier-1 supplier environment

Technical Skills

Strong expertise in:

- GD&T; (ASME Y14.5)
- Tolerance stack-up analysis
- Dimensional Variation Analysis methods
- Hands-on experience with tools such as:
- 3DCS
- CETOL
- VisVSA or similar platforms

Domain Knowledge

Solid understanding of:

- Body-in-White closures interiors or vehicle systems
- Manufacturing and assembly variation
- Knowledge of statistical analysis methods such as Monte Carlo and worst-case analysis
- Familiarity with quality systems and automotive standards

Leadership Skills

- Proven experience leading technical teams
- Strong programme management and stakeholder engagement skills
- Effective communication across global and cross-functional teams
- Ability to drive problem-solving and decision-making

Required Experience:

Senior IC

📌 DVA Lead Engineer (Chennai)
🏢 Ford Motor
📍 Chennai