Design Industrialization Engineer

In this position...

We are looking for a degreed engineer with prior manufacturing experience and a strong quality background. Ideal candidates for this position will have technical expertise in High Pressure Die Casting, Greensand / SPM molding, CGI castings for powertrain, structural and EV vehicle applications and prior experience managing automotive suppliers for an OEM or experience supporting a supplier manufacturing site as a Quality Engineer.

Key responsibilities will include performing Casting Process new technology feasibility assessments & manufacturing assessments, resolving issues, developing robust industrialization plans, breaking capacity constraints, addressing systemic quality/warranty issues and delivering on APQP/PPAP. Building strong relationships with supplier partners will be critical for success and significant collaboration will be required with senior leaders in the Ford Product Development, Research, Supply Chain and STA team.

This will require excellent verbal and written communication skills and a passion for teamwork and collaboration.

The Ford Casting STA Team is committed to delivering a world class automotive supply base that produces best in class quality in the most efficient and cost-effective manner possible.

Our diverse Global Casting STA Team includes team members in North America, Europe, and Asia. It is comprised of manufacturing experts with specialties in body exterior, body interior, chassis, powertrain, and electrical. Together our team works to understand the changing manufacturing landscape, identify new opportunities, and take action to design and innovate for the future of mobility.

• Engagement with external suppliers to drive robust Casting manufacturing process standard execution to deliver quality and delivery excellence
• Collaborate with Research and PD to understand new technologies and how they might impact the supply base
• In depth Casting process feasibility analysis for new supplier sites, new technology and high-risk commodities
• Lead development, documentation and implementation of critical Design Industrialization STA deliverables during planning and execution
• Participate in Casting process standard governance, Tech Clubs, and supplier summits
• Provide Casting process technical support during issue resolution to cascade supplier systemic quality, capacity, delivery, and manufacturing lessons learned to prevent recurrence
• Collaborate with peers in Product Development, Research and Supply Chain to drive optimal sourcing decisions
• Conduct Launch Readiness Reviews at Supplier sites as per Ford’s Supplier Engagement Process for future model programs
• Conduct Manufacturing Site Assessments (MSA), identifying gaps, and establishing/monitoring CIAP’s (Continuous Improvement Action Plans)
• Conduct onsite evaluation visits for Priority commodities as per GPDS supplier engagement process for new programs
• Drive capacity/uplift actions with Suppliers in accordance with Global Capacity Planning (GCP) and Manufacturing Capacity Planning Volumes (MCPV) study requirements
• Review and approve Supplier Capacity Analysis Reports (CAR) ensuring compliance to capacity requirements
• Review supplier incremental tooling work plans ensuring that plans comply to PPAP (Production Part Approval Process) requirements
• Review and approve PPAP’s (Production Part Approval Process) for engineering changes, supplier driven (SREA) changes, and new tooled end items
• Drive on-time PPAP submissions ensuring that supplier project timing plans are on track
• Drive compliance to all organizational and corporate training requirements
• Drive robust Supplier Failure Mode Avoidance by Deep Diving:
  • DFMEA’s/PFMEA’s
  • Special Characteristics Agreements (SCCAF)
  • Control Plans

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