Failure Mode Avoidance Engineer

Ford Energy is a newly formed, wholly-owned subsidiary of Ford Motor Company dedicated to accelerating U.S. energy independence. Leveraging Ford’s century of manufacturing excellence and world-class battery energy storage systems (BESS) technology, Ford Energy designs, manufactures, and services grid-scale and commercial DC battery energy storage systems (BESS). Ford Energy is uniquely positioned to capture the growing demand for reliable, US-built energy storage systems.

We are not just building batteries; we are building the infrastructure for the next generation of the American grid.

Why Ford Energy? At Ford Energy, you have the backing of an industrial manufacturing powerhouse with the agility of a dedicated energy startup offering industry leading technology. We offer a competitive compensation package including performance-based bonuses, Ford vehicle discounts, and the opportunity to shape the energy strategy of one of the world's most iconic brands. Learn more at

In this position, the FMA (Failure Mode Avoidance) Engineer is the technical engine behind Ford Energy's 'design it right the first time' quality philosophy. This role owns the rigorous, structured processes — DFMEA, PFMEA, Robustness Reliability Cross-Check Lists (RRCL), and Special or Critical Characteristics Agreement Framework (SCCAF) — that identify and eliminate potential failure modes before they reach hardware, while ensuring proper linkage between all documents.

The FMA Engineer works at the intersection of systems architecture (using Model-Based Systems Engineering tools like Magic Draw), design engineering, and manufacturing to ensure failure avoidance is embedded from concept through production.

• FMA Process Leadership
• Plan, schedule, and facilitate DFMEA and PFMEA workshops across cross-functional design, systems, and manufacturing engineering teams.
• Ensure FMA activities are timed to influence design decisions (i.e., conducted early enough to shape architecture, not just document risk after the fact).
• Coach and train design/manufacturing engineers on FMA methodology to build organization-wide fluency.

• Bachelor's degree in Electrical, Mechanical, or Systems Engineering.
• 5+ years of hands-on expertise with DFMEA/PFMEA methodology;
  Six Sigma Green/Black Belt preferred.
• Experience with Model-Based Systems Engineering tools (Magic Draw or similar).
• Experience applying FMA methodology to high-voltage battery systems or power electronics.
• Six Sigma Black Belt or Master Black Belt certification.
• Familiarity with SCCAF/RRCL frameworks specifically (as used in automotive/Ford quality systems).
• Magic Draw (MBSE)
• DFMEA/PFMEA software (APIS IQ-RM, Relyence, or similar)
• PLM/requirements management integration tools
• Typical Career Path
  • Progression toward Senior FMA/Reliability Engineer, FMA Program Lead, or Supervisor, Systems Integration and FMA.
• Physical Demands & Working Conditions
  • This role is primarily performed in an office, laboratory, manufacturing, or supplier environment, depending on program needs.
  • Occasional work in high-voltage or industrial environments may be required, with appropriate training and personal protective equipment (PPE).
  • Ability and willingness to travel occasionally to support testing, supplier, manufacturing, or customer activities.
• Location & Travel
  • This position is based in Dearborn, Michigan.
  • Travel may be required to support supplier, manufacturing, laboratory, and customer activities.

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a change maker, a technical expert, a culture builder…or all of the above?

No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized backup child care and more
• Family building benefits including adoption and surrogacy expense reimbursement,…