A development engineer has the responsibility for coordinating delivery of the engineering attributes of a complete automobile (bus, car, truck, van, SUV, motorcycle etc.) as dictated by the automobile manufacturer, governmental regulations, and the customer who buys the product.
Much like the Systems Engineer, the development engineer is concerned with the interactions of all systems in the complete automobile. While there are multiple components and systems in an automobile that have to function as designed, they must also work in harmony with the complete automobile. As an example, the brake system's main function is to provide braking functionality to the automobile. Along with this, it must also provide an acceptable level of: pedal feel (spongy, stiff), brake system “noise” (squeal, shudder, etc.), and interaction with the ABS (anti-lock braking system)
Another aspect of the development engineer's job is a trade-off process required to deliver all of the automobile attributes at a certain acceptable level. An example of this is the trade-off between engine performance and fuel economy. While some customers are looking for maximum power from their engine, the automobile is still required to deliver an acceptable level of fuel economy. From the engine's perspective, these are opposing requirements. Engine performance is looking for maximum displacement (bigger, more power), while fuel economy is looking for a smaller displacement engine (ex: 1.4 L vs. 5.4 L). The engine size however, is not the only contributing factor to fuel economy and automobile performance. Different values come into play.
Other attributes that involve trade-offs include: automobile weight, aerodynamic drag, transmission gearing, emission control devices, handling/roadholding, ride quality, and tires.
The development engineer is also responsible for organizing automobile level testing, validation, and certification. Components and systems are designed and tested individually by the Product Engineer. The final evaluation is to be conducted at the automobile level to evaluate system to system interactions. As an example, the audio system (radio) needs to be evaluated at the automobile level. Interaction with other electronic components can cause interference. Heat dissipation of the system and ergonomic placement of the controls need to be evaluated. Sound quality in all seating positions needs to be provided at acceptable levels.
Manufacturing Engineers are responsible for ensuring proper production of the automotive components or complete vehicles. While the development engineers are responsible for the function of the vehicle, manufacturing engineers are responsible for the safe and effective production of the vehicle. This group of engineers consist of Process Engineers, Logistic Coordinators, Tooling Engineers, Robotics Engineers, and Assembly Planners.
In the automotive industry manufacturers are playing a larger role in the development stages of automotive components to ensure that the products are easy to manufacture. Design for Manufacturability in the automotive world is crucial to make certain whichever design is developed in the Research and Development Stage of automotive design. Once the design is established, the manufacturing engineers take over. They design the machinery and tooling necessary to build the automotive components or vehicle and establish the methods of how to mass-produce the product. It is the manufacturing engineers job to increase the efficiency of the automotive plant and to implement lean manufacturing techniques such as Six Sigma and Kaizen.
Other automotive engineers include those listed below:
- Aerodynamics engineers will often give guidance to the styling studio so that the shapes they design are aerodynamic, as well as attractive.
- Body engineers will also let the studio know if it is feasible to make the panels for their designs.
- Change control engineers make sure that all of the design and manufacturing changes that occur are organized, managed and implemented.
- Acoustics engineers are specific types of development engineers who do sound and aerodynamic testing to prevent loud cabin noises while the vehicle is on the road.
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