Process FMA Engineer

Powertrain Manufacturing Engineering Process Failure Mode Avoidance

We made history and now we work to transform the future – for our customers, our communities and our families. You'll see your work on the road every day, helping people move freely and pursue their dreams. At Ford, you can build more than vehicles. Come build what matters.

As part of our Manufacturing team, you'll help build the world-class, state-of-the-art smart vehicles we're known for. In our plants around the world, we're constantly developing new technologies and processes to further increase our efficiency. You'll get the satisfaction of making great products people use and love.

The Powertrain Manufacturing Engineering Process Failure Mode Avoidance (PTME FMA) and Prevent Recurrence Team is seeking a motivated professional to drive quality robustness across our engineering factory. Leveraging expertise in FMA deliverables including PFMEAs, Control Plans, error-proofing strategies, engineering standards, and new program launch requirements; you will support PTME launch teams through coaching, training, technical deep dives, and enhancements to engineering standards.

Additionally, you will collaborate with global teams to resolve powertrain launch quality concerns and execute continuous improvement initiatives.

Work directly with PTME and Global Quality teams to improve the Quality Operating System (QOS), update standard documents, enhance FMA process robustness, and lead continuous improvement training initiatives.

Key responsibilities include:

• FMA & Quality Deliverables: Assist in the development, review, and maintenance of Process FMA deliverables—including PFMEAs and Control Plans—to ensure alignment with corporate standards.
• Problem Solving & Root Cause Analysis: Support root cause analysis and permanent corrective action (PCA/PRA) processes using structured problem-solving tools such as 3-Legged 5-Why (3L5Y), 8D, and A3.
• Launch & Warranty Support: Conduct launch quality and warranty deep-dive reviews; to help identify recurring failure modes, risk areas, lessons learned, potential systemic improvements and ultimately support warranty reduction work streams.
• Lessons Learned & Best Practices: Collaborate with cross-functional partners (Product Development, Plant Quality, and Global Engineering) to support the development and implementation of best practices, drive continuous improvement and issue resolution document and cascade Quality Operating System (QOS) lessons learned into forward-model programs.
• Continuous Improvement & Audits: Support the update and enhancement of FMA tools, training materials, and ISO audit compliance activities across manufacturing engineering, including DRIM (Departmental Records Inventory Matrix) maintenance.
• Plant Support & Travel: Travel to Powertrain Manufacturing Plants as required (including occasional overnight stays) to support launch teams, deep dives, and plant quality initiatives.

Note:

Training will be provided for the above responsibilities and associated systems as needed.

Minimum Qualifications:

• Education & Technical Experience: Bachelor of Applied Science in Engineering degree (or equivalent) with a minimum of 5 years of experience in a manufacturing engineering discipline.
• Plant & Quality Background: Proven manufacturing and quality experience in a plant manufacturing environment, including direct experience in APQP (Advanced Product Quality Planning), PFMEA development, and Control Plans.
• Problem Solving & Analytics: Strong leadership, analytical, and structured problem-solving skills paired with an innovative, continuous improvement mindset.
• Communication & Coaching: Excellent verbal and written communication skills with the ability to teach, coach, and effectively present technical materials to peers and various levels of PTME leadership.
• Teamwork & Flexibility: Strong interpersonal skills with a proven track record of collaborating effectively within diverse, dynamic, cross-functional teams.
• Self-Motivation & Agility: Fast learner with self-motivation and initiative to proactively acquire technical knowledge independently via online documents and…