Frequently asked questions

Your responsibilities:

• Overall responsibility for planning, managing and implementing construction projects in the field of vehicle development
• Coordination of interdisciplinary development teams (e.g. CAD, simulation, validation)
• Ensuring compliance with processes, deadlines, costs and quality objectives (TCQ)
• Technical evaluation and approval of design solutions in coordination with customers and suppliers
• Conducting design reviews, FMEAs and change management
• Interface management with internal departments and external partners
• Preparation of project status reports and presentations for management

The project manager is responsible for the technical, scheduling and financial aspects of a defined component group within a vehicle development project – from concept phase to series approval.

• Responsibility for development and integration of a component group (e.g. seats, doors, cockpit, chassis, body components)
• Coordination of all development activities within the component group in close collaboration with design, simulation, testing, procurement and suppliers
• Ensuring compliance with deadlines, costs and quality targets (TCQ)
• Creating and maintaining specifications, parts lists and technical documents
• Carrying out design reviews, FMEAs, tolerance analyses and change management
• Interface management with adjacent components and systems
• Support for approval processes, prototype construction and series launch
• Reporting and status tracking to project management and executives

A Resident Engineer acts as a link between the vehicle manufacturer and suppliers. They are occasionally present at the suppliers’ sites and ensure that the delivered components meet the manufacturer’s requirements and specifications. Their responsibilities include:

• Technical support: Providing technical support and solving problems in the development and production of vehicle components.
• Quality control: In the case of identified quality deviations, necessary corrective and preventive measures must be initiated to restore compliance with the defined component specifications.
• Communication: Close cooperation and communication with the engineering teams of the manufacturer and suppliers to ensure all requirements are met.
• Project management: Coordination and monitoring of projects to ensure they are completed on time and within budget.

FMEA (Failure Mode and Effects Analysis) is a systematic method for risk assessment in product and process development. The aim is to identify potential failures early, evaluate their impact and define suitable measures to prevent or reduce failures. The most common FMEA variants used in series production are D-FMEA and P-FMEA:

The Finite Element Method is used to:

• simulate mechanical loads (e.g. deformation, stress, fracture)
• simulate thermal effects (e.g. temperature distribution, heat conduction)
• simulate acoustic properties (e.g. vibrations, noise development)
• simulate crash behavior (e.g. energy absorption, crumple zones)

– before a physical prototype is built.

Examples of application in vehicle development:

• Body structure: Crash simulation, stiffness, lightweight design
• Chassis: Load on control arms, springs, dampers
• Interior: Acoustics, comfort, airflow
• E-mobility: Thermal management of batteries and power electronics

Advantages of FEM:

• Early error detection
• Cost and time savings due to fewer prototypes
• Optimization of weight, material usage and safety
• Support for DFMEA and component approvals

In vehicle development, prototypes play a central role. They serve as physical or virtual early versions of a vehicle to test concepts, functions and quality before series production begins.

Objectives of using prototypes:

1. Technical validation

• Testing functionality, safety and reliability
• Testing driving behavior, braking, steering, drivetrain systems

2. Error detection and optimization

• Early detection of design or manufacturing defects
• Opportunity for adjustments before production start

3. Compliance with legal requirements

• Conducting crash tests, emission and noise tests
• Preparation for homologation and approval

4. Testing under real conditions

• Tests at extreme temperatures, altitudes, road conditions
• Simulation of long-term loads

5. Fine-tuning comfort and acoustics

• Optimization of NVH (Noise, Vibration, Harshness)
• Fine-tuning of interior climate, seating, infotainment

A TISAX-certified engineering company offers the following benefits:

• Trust and credibility: The TISAX certification demonstrates that the company meets high standards regarding information security and data protection. This creates trust with customers and business partners.
• Competitive advantage: Companies with TISAX certification have a competitive edge, as many automotive manufacturers and suppliers require certification for cooperation.
• Risk minimization: By complying with TISAX standards, risks related to information security and data protection are reduced, increasing operational security.
• Efficiency increase: Implementing TISAX standards leads to more efficient processes and better organization, which improves overall company performance.
• Legal compliance: TISAX certification helps companies meet legal and regulatory requirements related to information security and data protection.

A vehicle developer designs, develops and tests vehicle components or entire systems. They work on design, simulation, prototyping and optimization.

Automotive engineering, mechanical engineering, production engineering, automotive engineering, electrical engineering, automotive design or automotive management.

Yes, it is demanding because it includes many technical subjects such as mathematics, physics and mechanics.

Bachelor’s: 6–7 semesters (3–3.5 years), Master’s: an additional 3–4 semesters (1.5–2 years).

An engineer who works on development, design, testing and optimization of vehicles.

Technical services such as product development, design, simulation, prototyping and project management.

A company that takes on technical development tasks for other companies.

Vehicle development, design, manufacturing, powertrain, electronics, testing and validation.

Structural design, mechanical design, electrical design.

You design technical products using CAD, create models, select materials and produce drawings.

The development and layout of vehicle components and systems using CAD and simulation tools.

An early, functional model of a vehicle or component used for testing and further development.

They manufacture and assemble prototypes of vehicle parts or entire vehicles for testing and development.

Vehicles built for testing purposes before entering series production.

A team leader in simultaneous engineering who coordinates collaboration between development and production.

A technical project manager who leads cross-functional teams in the development process.

Yes, a team leader has professional leadership responsibility for a team and coordinates tasks and goals.

A technical contact person on-site with the customer who supports development and quality issues.

Depending on experience, approx. €50,000–80,000 gross annually in Germany.

A resident is a technical representative of a company at the customer’s site, often for quality assurance or development.

The creation of digital 2D or 3D models of technical components using CAD software.

Computer Aided Design – computer-based design and drafting of technical products.

It requires technical understanding, but it is well learnable with practice and training.

Digital methods for the design (CAD) and manufacturing (CAM) of dental prostheses.

A limited number of units of a product, usually under 1,000 pieces.

Depending on the industry, usually up to approx. 500–1,000 units – no standard definition.

Between €60,000 and €100,000 gross annually, depending on experience and responsibility.

They plan, manage and monitor projects in vehicle development or production.

Defining goals, time and resource planning, team coordination, risk management, controlling.

The organization and control of development or production projects in the automotive sector.

Original Equipment Manufacturer – a vehicle manufacturer like BMW, VW or Mercedes.

A company that produces vehicles or parts under its own brand.

A manufacturer that develops and produces complete vehicles or systems.

Companies that process sensitive data for OEMs – e.g. development service providers or suppliers.

Many German OEMs such as VW, BMW, Mercedes-Benz, Audi – especially for development projects.

Accredited audit providers such as TÜV, DEKRA or SGS, approved by the ENX Association.

Depending on company size and scope approx. €5,000 to €20,000 – including preparation and audit.

Technical services such as development, design, simulation, testing, or project management provided by specialized companies.

Engineering Services in German means: engineering services or technical development services.

Mechanical engineering, electrical engineering, automotive engineering, software development, process engineering, medical technology, aerospace engineering.

Services where engineers apply their expertise on a project basis for other companies – e.g., in development, design, or consulting.

You develop, design, test, or optimize technical products, systems, or processes.

Planning, development, design, simulation, project management, quality assurance, technical consulting.

Services where engineers apply their expertise on a project basis for other companies – e.g., in development, design, or consulting.

A company that handles technical development tasks for other firms.

1. Initiation, 2. Planning, 3. Execution, 4. Monitoring & Controlling, 5. Closure.

1. Scope, 2. Time, 3. Cost, 4. Quality, 5. Resources, 6. Communication.

Defining objectives, planning, resource management, risk management, communication, controlling, closure.

Between €45,000 and €100,000 annually – depending on industry, experience, and position.

Development, design, production, assembly, electronics, software, testing, quality assurance.

Mechanical, electrical, electronic, structural, and software-based designs.

You design technical products, create CAD models, calculate components, and prepare manufacturing documentation.

The development and design of vehicle components such as body, chassis, drivetrain, or interior.

An early, functional model of a vehicle or component used for testing and further development.

They manufacture and assemble experimental models and prototypes for testing and development.

Vehicles built for testing purposes before mass production.

Manufacturing by layering material – e.g., 3D printing for parts or prototypes.

3D printing a lightweight component from plastic or metal.

Manufacturing processes where material is added – e.g., FDM, SLS, SLA, binder jetting.

According to ISO/ASTM, there are 7 main methods (e.g., material extrusion, powder bed fusion, etc.).

A technical contact who works directly on-site at the customer’s location and supports development projects.

Between €50,000 and €80,000 annually – depending on experience and industry.

Generally: a person who works permanently at a location. In engineering: a contact person at the customer’s site.

DFMEA (Design-FMEA) refers to product design, while FMEA in general also covers processes (PFMEA).

Usually the development team, often in collaboration with quality assurance and design.

Yes, DFMEA is part of the PPAP documentation (Production Part Approval Process).

An interdisciplinary team from development, quality, manufacturing, and possibly purchasing.

A rotating workpiece is machined with computer-controlled tools to produce precise shapes.

A machining process where computer-controlled lathes are used.

A machining process where the workpiece rotates and the tool remains stationary.

Between €50 and €120 – depending on machine, material, complexity, and quantity.

Improving products, processes, or systems in terms of efficiency, cost, quality, or performance.

Lean management, Six Sigma, Kaizen, value stream mapping, 5S, PDCA cycle.

Analyze processes, identify weaknesses, implement improvements, and measure results.

Yes, lean management is a method for continuous improvement and process optimization.

An international standard for quality management systems – it defines requirements for processes and quality.

Companies must document, monitor, and continuously improve their processes.

Proof that a company meets certain standards (e.g., ISO 9001).

Between €3,000 and €15,000 – depending on company size and effort.

Yes, Volkswagen is TISAX certified.

Yes, BMW is TISAX certified.

No, Microsoft itself is not TISAX certified, but many of its cloud services can be used in TISAX-compliant ways.

Yes, TISAX is an internationally recognized standard for information security in the automotive industry.

Engineering services are specialized technical services such as design, development, simulation, project management, or quality assurance provided by engineers.

An engineering service company offers technical development and consulting services to other businesses, e.g., in the automotive, aerospace, or mechanical engineering industries.

Engineering services include technical services such as product development, design, simulation, prototyping, and project support by engineers.

‘Engineering services’ in German means ‘Ingenieur-Dienstleistungen’ – that is, technical development and consulting services.

Typical subfields include mechanical engineering, electrical engineering, automotive engineering, software development, process engineering, mechatronics, and civil engineering.

An OEM partner is a company that collaborates with an original equipment manufacturer (OEM) to provide components, systems, or services for their products.

An OEM partner is a supplier or service provider that works closely with a vehicle manufacturer (OEM), e.g., in development or production.

OEM vehicles are vehicles produced directly by the original equipment manufacturer and sold under their brand.

The OEM business model is based on a manufacturer selling products under its own brand while many components come from suppliers.

Yes, TISAX is an internationally recognized audit and exchange procedure for information security in the automotive industry.

Important certifications include ISO 9001, IATF 16949, ISO 14001, ISO 27001, TISAX, and VDA 6.3.

Many companies worldwide, especially in the industrial sector, are certified according to ISO 9001 – including car manufacturers and suppliers.

Transparency means that all participants are informed at all times about goals, progress, risks, and decisions in the project.

Transparent communication means communicating openly, honestly, and comprehensibly – without withholding information.

Project culture describes the shared values, behaviors, and communication styles within a project team.

In a figurative sense, ‘transparent’ means that something is understandable, open, and clear – e.g., decisions or processes.