Experience

Engineering Supervisor — Powerpack Application Team

R&D Engineering Leader

• R&D team leadership & scaling: leading an application team of 14 engineers responsible for Powerpack design and mechatronic integration in Electric Power Steering products across the full lifecycle, from project nomination to SOP.
• OEM & supplier partnership: directing technical and strategic discussions with major OEMs (BMW, Stellantis, Tesla, Renault) and global component suppliers (Mahle, Nidec, Flextronics, LG, Lear, Kimball).
• Knowledge transfer & process setup: managing and executing engineering knowledge transfer from global technical centres in the USA and China to the local Polish R&D team.
• Change management: serving as a Change Leader on the Divisional Change Board, evaluating and approving design and process engineering changes.
• VAVE & cost optimisation: coordinating cost-improvement initiatives for mass-production projects, balancing technical requirements against business goals.
• Cross-functional leadership: partnering with Sales, Supply Chain, Manufacturing and Quality; member of the Process Improvements Board and primary escalation point for technical issue resolution.

Design Release Engineer — Product & Mechatronic Integration

• Design responsibility & integration: led mechanical design, CAD modelling and mechatronic integration for Modular Power Pack components — motor housings, covers and full assemblies.
• System requirements & validation: balanced top-down system requirements against key component metrics using FEA/CFD models, modal analysis and prototype evaluation.
• Advanced analysis: conducted complex 3D tolerance stack-up analyses (Teamcenter Variation Analysis) and defined GD&T standards on engineering drawings (ASME Y14.5).
• New project pursuits: coordinated technical requirements for new pursuits with Nexteer Customer Service Centres across Europe — Munich, Rüsselsheim, Paris.
• Supplier & purchasing collaboration: selected qualified production suppliers alongside Purchasing and Supplier Quality, ensuring parts arrived on time and compliant with drawings and BOM.
• Quality & risk mitigation: developed and executed DFMEA, PFMEA, DFM, DRBFM and Six Sigma methodologies to support design revisions and prevent failures.

Test Manager — Product Validation

• Customer validation & product release: coordinated customer validation requirements, defined sample quantities and managed variant splits for full product-release compliance.
• Laboratory coordination: partnered with multidisciplinary validation laboratories covering EMC, electrical, environmental, mechanical, NVH and functional testing.
• Client reporting & resource management: prioritised laboratory resources against critical milestones and reported validation progress directly to OEM customers.
• Continuous improvement: folded lessons learned back into test specifications and operational instructions.

Product Engineer — Mechatronic Integration & Mechanical Design

• Mechatronic system integration: led the mechanical integration of Modular Power Packs — electric motor, controller, ECAD/MCAD interfaces — for EPS systems.
• Mechanical design: managed design projects for high-precision plastic components, die-cast metal parts with post-machining, electrical headers and wire harnesses.
• Tolerance analysis & standards: executed 3D tolerance stack-up analyses and defined GD&T standards (ASME Y14.5).
• Cost reduction: drove VAVE initiatives in close collaboration with ECAD, Manufacturing and Purchasing.

Design Engineer — Sensors & Switches Team

• Product design & technical ownership: primary technical lead for brake-pad wear sensors and sealed electrical transmission connectors (Connecting Bridges) for Automated Manual Transmission truck units.
• Component design & standards: designed high-precision plastic and die-cast metal components, defining geometric tolerances to ISO 1101.
• Cross-functional CAD leadership: provided CAD and design support across the team for parking-assistance, wheel-pressure, speed and relay sensors.
• Problem solving & supplier collaboration: resolved complex quality issues using QR6σ, Pugh decision matrices and root-cause methodologies with global suppliers.
• Validation & customer support: planned component testing procedures and supported commercial-vehicle OEMs directly.

Mechanical Engineer & Reliability Specialist

• Engineering & concept development: prepared preliminary technical concepts, created 3D models and manufacturing drawings, and led component modification projects in international teams.
• Quality & problem solving: facilitated DFMEA sessions and resolved engineering issues using A3, 5 Whys and Pugh matrices.
• Testing & reliability validation: defined test conditions, ran hydraulic and reliability testing on prototype dishwashers, and analysed failure modes to refine part designs.
• Cross-functional collaboration: partnered with Procurement, Marketing, Laboratories and Industrial Designers on new product development.

• Engineering team scaling & mentorship
• OEM technical escalation leadership
• Global knowledge transfer (USA, China, EU)
• Divisional Change Board leadership
• VAVE & cost-optimisation strategies

• Electric Power Steering Powerpack integration
• GD&T standards (ASME Y14.5 & ISO 1101)
• 3D tolerance stack-up (Teamcenter Variation Analysis)
• FEA structural & CFD thermal analysis
• Precision die-casting & injection moulding

• DFMEA, PFMEA, DFM & DRBFM
• Six Sigma & QR6σ problem solving
• EMC, NVH, environmental & mechanical testing
• Root-cause analysis (5 Whys, A3)
• Customer validation & product-release sign-off