Powertrain Technical Project Lead - Engine, Surrey

Description

Powertrain Technical Project Lead Consultant (Engine Systems Focus)

Purpose of the Role

Reporting to the Principal Engineer and working with the Technical Program Manager on powertrain engine system programs.
Working alongside Project Engineers in a small team, responsible for the delivery of internal combustion engine components (e.g., pistons, connecting rods, crankshafts, cylinder blocks, cylinder heads, valvetrain systems) into small volume, high-performance specialist vehicle programs.

Essential Criteria

"Cradle to Grave" approach - working within a cross-functional team from R&D stage, through concept, design release, production launch, and series production support to deliver full vehicle performance targets and contribute to overall business KPIs.
Responsible for releasing designs that meet the following targets through coordination of internal and external resources:
- Cost (piece, tooling, development & validation)
- Performance (durability, strength, efficiency, friction reduction, and combustion performance cascaded from full vehicle targets to component-level specifications)
- Timing
- Feasibility (supporting in-house manufacturing/assembly processes such as machining, casting, forging, and supplier capability)

Key Responsibilities

Engine System Delivery

Lead the development and integration of core engine mechanical components, including:
- Pistons and piston rings
- Connecting rods
- Crankshaft and bearings
- Cylinder block and liners
- Cylinder head and valvetrain
Ensure designs meet performance targets such as thermal/mechanical loads, fatigue life, lubrication requirements, and emissions compliance.

Problem Solving

Apply proactive problem avoidance at early stages (Risk Assessments, DFMEA, lessons learned).
Lead hands-on issue resolution during:
- Prototype builds
- Engine dyno testing
- Vehicle validation
- Series production
Address issues such as wear, NVH, durability failures, oil consumption, and tolerance stack-ups.

Reporting & Control

Manage and maintain accurate Bill of Materials (BOM):
- Part numbering and structuring
- Engineering change processes
Track and manage:
- Component weight (critical for performance targets)
- Costs (forecasting, risks, and opportunities)
- Program timing and delivery status

Cost Engineering

Provide rapid cost estimates to support early concept decisions for engine components.
Deliver detailed cost breakdowns (materials, machining, treatments, assembly).
Support sourcing decisions using market insight and value analysis.
Drive continuous improvement in cost modelling through benchmarking and supplier engagement.

Additional Requirements

CATIA V5 / V6 2D/3D skills with strong GD&T application experience.
High level of technical knowledge and experience in:
- Engine mechanical design and architecture
- Materials and manufacturing processes (casting, forging, machining, coatings)
- Engine testing (dyno, durability, performance validation)
- Production and industrialisation of engine components
SAP capability including:
- Engineering Release Management
- BOM structuring
- Cost management

Highlights

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