Validation and Testing Manager – Mechanical Components

The Validation and Testing Manager – Mechanical Components is responsible for leading the validation and verification of mechanical components and systems such as chassis parts, suspension components, brackets, mounts, and other structural and dynamic parts used in vehicles. This role ensures that all components meet performance, durability, safety, and regulatory requirements through rigorous testing and data analysis. The manager oversees the planning, execution, and reporting of test programs and manages a multidisciplinary team of test engineers and technicians.

Key Responsibilities:

1. Test Planning & Strategy

• Define validation strategies for mechanical components in line with functional requirements and industry standards.

• Develop and approve Design Validation Plans & Reports (DVP&R) based on program timelines and performance criteria.

• Ensure test plans address durability, thermal performance, vibration, fatigue, environmental, and abuse conditions.

2. Test Execution & Oversight

• Manage day-to-day operations of test labs, rigs, and field testing activities.

• Supervise setup, instrumentation, and execution of component, subsystem, and system-level tests.

• Review and approve test procedures, setup documentation, and safety protocols.

3. Data Analysis & Reporting

• Review and interpret test data, identify deviations, and lead root cause analysis with design and quality teams.

• Ensure timely and accurate documentation of test results, failure analysis, and final reports for design feedback and release.

4. Team Management & Development

• Lead a team of test engineers and technicians; manage workload, training, and performance.

• Ensure cross-functional collaboration with design, manufacturing, CAE, and quality teams for test-based decision-making.

• Foster a culture of safety, discipline, and continuous improvement within the test organization.

5. Equipment, Facility & Budget Oversight

• Ensure testing facilities, rigs, and equipment are calibrated, functional, and capable of supporting current and future program needs.

• Manage validation budgets, resource allocation, and capital investment planning.

Key Focus Areas:

• DVP&R Development and Execution
  (Component and system validation based on functional specs and durability targets)

• Durability, NVH, and Environmental Testing
  (Fatigue, thermal cycling, corrosion, vibration, road load simulations)

• Failure Analysis and Design Feedback
  (Root cause, corrective actions, design loop closures)

• Test Lab Management and Equipment Readiness
  (Facility uptime, instrumentation, calibration, upgrades)

• Data Acquisition and Reporting Tools
  (Sensor selection, data loggers, test automation, analysis software)

• Team Leadership and Cross-Functional Alignment
  (Close collaboration with product engineering, CAE, and manufacturing)

Qualifications:

• Bachelor’s or Master’s in Mechanical Engineering or related discipline.

• 8–12 years of experience in validation and testing of mechanical systems or automotive components.

• Strong knowledge of mechanical testing methodologies, instrumentation, and data analysis.

• Familiarity with industry standards (ISO, SAE, ASTM) and regulatory compliance requirements.

• Experience with DVP&R, FMEA, root cause analysis, and reporting tools.

• Strong leadership, communication, and problem-solving skills.

Preferred Experience:

• Experience in the automotive, aerospace, or heavy equipment sectors

• Hands-on knowledge of test lab operations and environmental chambers

• Familiarity with fatigue life prediction and correlation between CAE and physical testing

• Experience managing external test vendors and contract labs