Manufacturing Engineer – Battery Pack Assembly

Responsibilities

• End-to-End Execution:
  Lead the engineering of line layouts and implement manufacturing processes for assembly of battery packs.
• Early Feasibility:
  Provide technical manufacturing input during product concept phases to influence architecture, assembly feasibility, and scalability.
• Equipment Design & Buyoff:
  Collaborate with OEMs and automation partners to design manufacturing equipment and tooling. Lead on-site equipment buyoff per acceptance procedures.
• Plant Launch:
  Lead equipment installation and commissioning. Support plant operations through SOP (Start of Production) and the "Rate of Climb" phase to achieve OEE, cycle time, and JPH targets.
• DFM (Design for Manufacturability):
  Drive simultaneous engineering with Product Development, Purchasing, and Suppliers to ensure products are optimized for high-volume manufacturing.
• Risk Mitigation:
  Lead the development of PFMEA (Process Failure Mode and Effects Analysis), Control Plans, and associated gauging/inspection requirements.
• Standards Compliance:
  Ensure all systems align with Ford BME standards, including MDS/MPS (Manufacturing Design/Process Standards) and Bill of Process (BoP).
• Joining Technologies:
  Specify and validate joining processes, including fastening systems, adhesives/sealants, riveting, and specialty battery joining methods.
• Digital Manufacturing:
  Utilize digital tools and DPA5 workflows, including AutoCAD, Team Center, 3DX, and Siemens PLM, for layout development, simulation, and virtual commissioning.
• Quality & Traceability:
  Implement vision systems, error-proofing, and data traceability solutions to ensure dimensional robustness and E2KS compliance.
• Technical Specifications:
  Develop Enquiry Specifications and provide technical support during supplier quoting and recap reviews.
• Change Management:
  Own the technical change management process to ensure Quality, Cost, and Timing targets are met.
• Documentation:
  Create detailed Manufacturing Instructions and drawings.

• Education:
  
  Bachelor’s degree in Engineering (Manufacturing, Mechanical, Industrial, Electrical, or related).
• Experience:
  
  2+ years of manufacturing engineering experience in assembly or automation-intensive environments.
• Project Execution:
  Experience implementing specialized manufacturing lines or large-scale capital projects.
• Technical Tools:
  Proficiency in AutoCAD and experience with simulation or digital manufacturing tools (e.g., Siemens PLM, 3DX, Team Center).
• Communication:
  Strong verbal and written communication skills for interacting with suppliers and cross-functional teams.
• Mobility:
  Ability to travel and support on-site launches at manufacturing facilities.
• Preferred Qualifications:
  
  Master’s degree in Engineering.
• Specific experience in battery cell, module, or pack assembly processes.
• Strong understanding of GDT stack-ups and dimensional robustness.
• Proficiency in Joining Technologies (dispense systems, fastening, bolt feeders, welding).
• Experience with vision systems equipment and related error proofing.
• Knowledge of Machine Monitoring Systems and constraint analysis techniques.
• Familiarity with Ford BME governance, DPA5, and MDS/MPS standards.