Cell-to-Pack Technical Specialist

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We are the movers of the world and the makers of the future. We get up every day, roll up our sleeves and build a better world – together. At Ford, we’re all a part of something bigger than ourselves. Are you ready to change the way the world moves?

Ford is rapidly scaling next‑generation battery manufacturing, including cell‑to‑pack architectures for our future electric vehicles. We are seeking a Process Engineering Technical Specialist to provide technical leadership to 100+ engineers within our battery manufacturing organization and shape the production of the next generation of electric vehicles.

• Establish a complete battery manufacturing process for cell‑to‑pack assembly, including production line layout and launch.
• Drive design for manufacturing (DFM) for new cell‑to‑pack products, leading simultaneous engineering with product, purchasing, and suppliers.
• Develop high‑ROI automation solutions by collaborating with technology partners to improve productivity.
• Collaborate with industrial engineering to define cycle time, OEE, and key performance indicators (KPIs) and develop operating strategies.
• Develop and maintain complete documentation packages, including process instructions, technical drawings, maintenance plans, spare part lists, and training manuals.
• Proactively manage project schedules, budgets, and change requests to deliver projects on time and within budget.

• Lead the development of quality control methods, including PFMEA, gauge R&R studies, and inspection procedures.
• Define critical‑to‑quality characteristics, prevention/detection methods, and inspection acceptance criteria; establish gauge strategies.
• Ensure compliance with Ford’s safety standards and industry best practices for high‑voltage battery manufacturing.

• Partner with cell and pack product design teams to provide early input for design for manufacturability, simplifying designs and optimizing material selection.
• Analyze critical dimensions and tolerances to recommend practical tolerances achieving balanced design needs and manufacturing feasibility.
• Develop and validate manufacturing processes, conduct pilot runs, and provide technical support for new product launches.
• Communicate effectively with stakeholders and OEM partners to ensure project success and timely delivery.
• Support problem‑solving activities (8D, 5‑Why, Ishikawa) for build issues, field returns, and validation of test failures.
• Travel to domestic and international manufacturing facilities to collaborate with team members and oversee vendor rollout.

• Support pilot builds, pre‑production, and launch events at global sites.
• Develop documentation and training for plant teams: process instructions, troubleshooting guides, maintenance best practices, and safety procedures.
• Drive continuous improvement of OEE, cycle time, yield, scrap, and consumable usage.
• Benchmark industry best practices and emerging technologies in battery cell‑to‑pack assembly and recommend adoption paths for Ford.

• Bachelor’s degree in Mechanical Engineering or a relevant engineering discipline.
• 8+ years of experience developing new automated manufacturing processes in the battery and/or automotive industry, implementing large‑scale projects as a Manufacturing Engineer or Project Manager.
• Demonstrated experience developing and optimizing welding or joining processes (laser, resistance, TIG/MIG, ultrasonic, etc.).
• Metallurgical evaluation of welds (microstructure, defects, joint design considerations).
• Running structured experiments and analyzing data (DoE, regression, statistical analysis).
• Understanding of cell‑to‑pack assembly processes (cylindrical or prismatic form factor preferred).
• Experience designing mechanical equipment, fixturing, and tooling with digital tools and tolerance stack‑up and GD&T.
• Deep knowledge of assembly systems and process flow with the ability to identify and utilize new technologies to improve manufacturing processes.
• Proficiency with engineering…