MP&L Forward Model Process Engineer

Responsibilities

• Partner closely with base Material Flow, Packaging, and Automation Engineers during the forward model phase to review Plan for Every Part (PFEP), 3D Layout & Flow Simulation, Automation Process Application ensuring they align with global MP&L standards.
• Own the continuous improvement and authoring of MP&L deployment procedures. Translate complex engineering designs into standardized operating procedures (SOPs), Bill of Process (BoP) guidelines, and standard work instructions for plant floor execution.
• Lead and facilitate comprehensive Failure Mode Effects Analysis (FMEA) for new model program material flow and packaging. Identify critical points of failure across automated systems (AMRs/AGVs/ASRS’s), packaging constraints, and material handling bottlenecks.
• For all critical risks and potential disruptions identified in operations, establish, document, and validate backup procedures. Ensure the plant can seamlessly transition to alternative or manual workflows while maintaining safety, quality, and service levels without interruptions.
• Collaborate with Manufacturing, Quality, and Plant Operations to ensure risk-mitigation strategies and backup procedures are integrated into early facility designs and budget planning.
• Lead the physical  dry running  and stress-testing of both primary and backup procedures during pre-production launch phases. Train plant logistics personnel on fallback procedures to ensure operational readiness before Start of Production (SOP).

• Bachelor’s degree in Industrial Engineering, Manufacturing Engineering, Supply Chain/Logistics, or a related technical field.
• 1 to 3 years of experience in an advanced manufacturing, automotive, or heavy industry logistics environment.
• Strong foundational knowledge of PFMEA (Process Failure Mode and Effects Analysis) methodologies and risk assessment tools.
• Experience collaborating with or supporting specialized engineering teams (such as packaging design, facility layout/material flow, or robotics/automation).
• Exceptional technical writing skills with a proven track record of developing clear, highly structured engineering standards, SOPs, or contingency plans.
• Strong cross-functional leadership skills, with the ability to facilitate workshops, drive consensus, and bridge technical gaps between engineering and plant operations.
• Ability and willingness to travel domestically and internationally to support plant launch, benchmarking, and validation activities.
• Advanced degree in Industrial Engineering, Manufacturing Engineering, or Supply Chain/Logistics.
• Experience in Business Continuity Planning (BCP) or disaster recovery planning within a high-volume manufacturing environment.
• Deep understanding of automation failure modes (e.g., PLC controls issues, industrial network drops, AMR fleet management software failures) and manual recovery protocols.
• Familiarity with Lean Manufacturing, Six Sigma methodologies, and formal change management processes.
• Experience utilizing AI-powered tools to integrate in problem solving and solution generation.
• Knowledge of Ford-specific software systems and standards, including GSPAS/APT, WERS, FEDE, and Ford MOS (Manufacturing Operating System) standards.