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Modular Product Design Engineer

Location: York, PA (or as applicable)
Department: Engineering

Position Summary

The Modular Product Design Engineer is a key technical leader responsible for designing new products and product families using principles of modularity. This role focuses on creating scalable, configurable products by defining and maintaining module designs, interfaces, and variants in alignment with Modular Management methodologies, PALMA software, and product configurators.

This engineer works cross‑functionally with Product Management, Project Management, Sales, Manufacturing, Sourcing, and Engineering to translate market needs into a robust modular product plan, execute detailed design and validation activities, and protect the long‑term integrity and value of the modular product architecture.

Key Objectives / Outcomes

• Deliver new product designs built on principles of modularity that enable reuse, scalability, and configurability.
• Develop and maintain modules, interfaces, and module variants that align with defined modular strategies and governance rules.
• Support product launch waves (CTO / DTO / ETO) through PALMA and product configurators in line w Product leadership targets.
• Enable faster time‑to‑market, reduced complexity, and sustainable cost and margin improvements through modular design.

Core Responsibilities

1) Modular Product Architecture & Design

• Design HVAC products and sub‑systems using modular principles, including module boundaries, controlled interfaces, and defined variant rules.
• Execute Module Design and Modular Modeling activities that transfer architectural intent into production‑ready CAD designs.
• Develop and maintain module skeletons, space claims, interfaces, and envelopes that preserve architectural integrity.
• Ensure designs comply with modular governance rules to prevent architectural erosion over time.

2) PALMA, Configurator & Product Planning

• Use PALMA software to define, manage, and maintain module variants, readiness levels, and launch waves.
• Support and refine product configurators that translate customer requirements and market segmentation into valid product configurations.
• Develop and maintain product plans that align module lifecycle (phase‑in / phase‑out) with business and market objectives.

3) CAD Design & Documentation (Hands‑On)

• Create 3D models, assemblies, and 2D drawings for modules and module variants using Autodesk Inventor, AutoCAD, and Vault.
• Ensure drawings and models meet internal standards for producibility, configurability, and change control.
• Support generation of CAD structures from configurator outputs to enable efficient product development and ERP integration.

4) Cross‑Functional Collaboration

• Work closely with Product Managers to translate market needs, value propositions, and product roadmaps into modular design requirements.
• Partner with Project Managers to execute design, validation, and launch activities on schedule.
• Collaborate with Sales to support configured offerings and manage technical trade‑offs.
• Engage Manufacturing, Sourcing, and Quality early to ensure DFM/DFA, cost targets, and supplier strategies are met.

5) Cost, Quality & Risk Management

• Perform cost analysis at module and product levels to support design‑to‑cost objectives.
• Lead or participate in DFMEA / PFMEA activities to manage design risk across modules and interfaces.
• Apply Lean / Toyota / Six Sigma / Kaizen principles to improve product and process efficiency and reduce waste.

6) Validation & Launch Support

• Lead or support prototype builds, design verification, and validation testing for new modules and product configurations.
• Ensure modular designs meet performance, reliability, regulatory, and customer requirements prior to release.
• Support production ramp‑up and continuous improvement activities post‑launch.

Required Qualifications

• Bachelor’s degree in Mechanical Engineering (or closely related field).
• 5+ years engineering experience in HVAC or similar electro‑mechanical manufacturing environments.
• Experience with top-down design methodology.
• Experience with components such as coils, sheet metal assemblies, electrical panels, and wiring harnesses.
• Strong hands‑on CAD capability using Autodesk Inventor / AutoCAD / Vault.
• Solid proficiency with Microsoft Office (Excel, PowerPoint, Word).
• Demonstrated ability to work independently while collaborating effectively in cross‑functional teams.

Preferred Qualifications

• Direct experience with modular product architecture, Modular Function Deployment (MFD), or Modular Management methodologies.
• Hands‑on experience using PALMA software and/or similar rules‑based product configurators.
• Experience leading or facilitating FMEA, Kaizen, Lean, Toyota Production System, or Six Sigma initiatives.
• Background in cost reduction or complexity reduction through product architecture and standardization.

Key Competencies

• Systems thinker with strong understanding of modularity and product architectures.
• Results‑driven with a continuous improvement mindset
• Excellent technical communication and documentation skills
• Comfortable operating between strategy (product plan, architecture) and execution (detailed CAD design)