Variation Analysis; Post-Final Design Judgement, FDJ Engineer

Variation Analysis (Post-Final Design Judgement, FDJ) Engineer

Dearborn, MI, United States (Hybrid)

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Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life. We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more!

In this position...
Ford is expanding our Dimensional Systems capability with a team purpose-built to drive post-Design Freeze execution across vehicle systems during launch and current production. This group owns post-Design Freeze variation analysis encompassing all interior and exterior component and assembly design and tolerance changes, certification of checking fixtures, data-driven management of tolerance concessions and production dimensional issues in partnership with suppliers and plant teams.

While you will support pre-Design Freeze activities for purchased assemblies, the primary focus of this role is post-Design Freeze readiness and execution across both purchased and in-house engineered components and assemblies.

As a Dimensional Systems Variation Analysis Engineer, you will develop and apply 3

DVSA models to validate component and assembly stack-ups, optimize tooling and fixture strategies, and quantify the impact of tolerance relief and design changes on vehicle fit and function. You will support APQP/PPAP-aligned dimensional deliverables through tool tryout and key build events, disposition deviations based on production data, and drive corrective actions to achieve robust launch capability.

This role is hybrid/onsite as program and launch phases require, with close collaboration at Ford facilities, suppliers, and manufacturing plants. Expect travel of approximately 10–20% within North America, with increased onsite presence during tool tryout, PPAP, and key build events.

What you'll do...

Post Design Freeze

Review and validate checking fixture designs for interior and exterior components/assemblies to ensure alignment with GD&T requirements.

Ensure all significant and critical characteristics are captured and measurable in the gauge.

Participate in digital and physical gauge certification.

Validate downstream fit and function of proposed component design changes using 3D-VSA.

Quantify and manage tolerance concessions across build events; assess potential impact on vehicle fit/function and align with APQP/PPAP requirements.

Analyze internal and supplier production data to identify tolerance improvement opportunities and implement dimensional enablers for non-compliant requirements.

Provide on-site support at suppliers and Ford plants for dimensional issues during new program launch.

Lead cross-functional problem-solving (D&R, Manufacturing, Quality, PVT, Suppliers) to determine root cause and implement corrective actions.

Pre Design Freeze

Develop assembly datum strategies and define drawing GD&T in CATIA/3DX for purchased assemblies (e.g., seat frames, cross-car beams, bumper beams).

Define and document process flows for purchased assemblies, ensuring consistent datum schemes and feature usage across components, tooling, and assembly operations.

Perform 3D-VSA studies (Vis-VSA) to predict system capability against appearance and functional requirements.

Identify and recommend improvements in tooling, processing and fixture strategies.

Correlate simulation to measurement data and refine models for accuracy.

You'll have...
Bachelor's degree in engineering or equivalent experience.
3+ years of experience in Dimensional Management Engineering/Analysis or equivalent field.

Even better, you may have...
Master's in Engineering.
3+ years performing 3D variation analysis (Vis-VSA, 3

DCS, or similar).
Strong knowledge of GD&T (ASME Y14.5) and tolerance stack methods.

Experience…