ICE Powertrain & Thermal Systems Engineering; IPTSE Quality​/Design Release Engineer – Tim

Job Description

The Quality/Design Release Engineer focuses on issues with the engine and thermal systems that manifest later in product life. The role requires utilizing best practice problem solving to quickly determine root cause, develop strategies and tools to catch issues sooner, develop new designs, execute test plans that ensure such issues are averted, and support efficient and robust service solutions.

The specific areas/sub-systems of responsibility would be within the base engine/long block and would be defined at the point of employment and joining the base engine team based on the successful candidate’s skill set and experience coupled with the skill set of the existing team. Examples of the base engine/long block sub-systems include:

• Cylinder Block
• Heads
• PCV
• EGR
• Sealing
• Covers
• Valve train
• VCTs
• Cam Drive
• Piston and Rod
• Rotating System
• Oil Pump & Lubrication
• Engine Bearings

The D&R Engineer is responsible for managing product release CAD and BOM structures, including assembly positioning and mass attribute analysis, facilitating supplier data integration and developing CAD studies to support and drive design improvements. The D&R Engineer will also use product check-in/check-out processes, version control, data release, and change management within Ford’s PLM ecosystem, and perform feasibility analyses using CAD tools such as draft angle analysis, undercut detection, minimum bend radius validation for sheet metal, clearance checks, and support manufacturing and machining requirements.

• Lead/support High Time in Service Quality Projects using Design for Six Sigma / 8D processes on aggressive timelines to support IPTSE’s warranty spend and failure rate reduction targets.
• Evaluate high warranty spend/failure rate subsystems and engine/vehicle applications with a focus on issues that contribute to >12 MIS warranty and/or are design/physics related versus supplier quality/manufacturing defect related.
• Work through the Define, Characterize, Optimize, and Verify phases of the DFSS process including root cause identification, verification, implementation of corrective actions, and prevention of recurrence.
• Design, execute, or coordinate analytical and physical testing from component bench level to full powertrain/vehicle testing to identify root cause, replicate quality issues, and validate fixes.
• Identify and document lessons learned for knowledge preservation.

• Lead new/forward model product development of the base engine sub system for new engine platforms.
• Design, develop, and release components.
• Lead/support resolution of major design, manufacturing, program, and launch issues as they arise.
• Create, complete, and approve supplier and Ford engine DVPs and oversee testing in support of robust validation.
• Lead Sub System CPMT activities.
• Support all program meetings (EPMT, Design Review, DPMT, change control, etc.).
• Lead drawing release and changes.
• Interface with Calibration, mating components, Purchasing, suppliers, and mfg/assembly plants.
• Prototype Build coordination: load forward model part numbers into system and ensure fit and function.
• Work directly with suppliers, Supplier Technical Assistance (STA), and launch teams to support programs and resolve quality issues, incl. travel both domestic and international when required.
• WERS coordination; alerts, concerns and notice processing.
• Develop and maintain CPMT documents, including appropriate quality documents (ESOW, DFMEA, PTDV, e3P, SCCAFs, Global Integrator, PPAP & PSWs, 543 Chart) for program specific sub-system responsibilities.

• Bachelor’s of Science Degree in Mechanical, Electrical, Material Science, or Aerospace Engineering.
• 2+ years of experience leading projects.
• 2+ years of experience with internal combustion engines or after-treatment systems in one or more of the following areas:
  Design, Test, Controls, Calibration.
• 6‑Sigma Green Belt, Black Belt or Design for Six Sigma experience is a plus.
• Familiarity/experience with Strategic Problem Solving.
• Familiarity/experience with Failure Mode Avoidance and Robustness and Reliability processes.
• Familiarity with quality…