Reliability Engineer

• Lead or support High Time in Service quality projects using Design for Six Sigma / 8D processes to reduce suspension warranty spend and failure rates
• Evaluate high-warranty-spend and high-failure-rate subsystems and engine/vehicle applications, focusing on issues contributing to over 12 MIS warranty and design/physics-related issues
• Execute Define, Characterize, Optimize, and Verify phases of the DFSS process
• Identify and verify root causes, implement interim and permanent corrective actions, perform read-across, and prevent recurrence
• Analyze warranty data and trends, conduct part-return analysis, and use physical understanding of suspension systems to identify corrective actions
• Develop relationships with dealerships and fleets to identify and resolve HTIS quality issues
• Design, execute, or coordinate analytical and physical testing from component bench level through full-vehicle testing
• Document lessons learned for knowledge preservation
• Analyze repair-cost variation and identify lower-cost repair opportunities
• Review and trial more efficient service procedures for field implementation
• Work with Ford Customer Service Department to implement tools supporting lower-cost repairs
• Lead engineering projects across suspension systems and vehicle lines contributing to yearly objectives
• Assess warranty tools and identify lower-cost repair opportunities
• Initiate appropriate teams and work plans for identified opportunities
• Present project status and results frequently to senior management
• Interface with quality, powerpack, core engineers, and technical specialists
• Maintain project documentation including 1-pagers, 6-panels, 8D reports, and management summaries
• Lead and attend team meetings
• Support cross-functional groups in identifying reliability challenges and tracking reliability through product launch
• Manage product-release CAD and BOM structures, supplier data integration, CAD studies, version control, data release, and change management
• Perform CAD feasibility analyses including draft-angle analysis, undercut detection, minimum bend-radius validation, and clearance checks

• BS in Engineering, Statistics, or a related field, or equivalent
• 1+ years of experience in reliability focused on automotive chassis product design
• 1 year of CAD experience
• Hands-on product testing experience preferred
• Battery Electric Vehicle experience preferred
• Manufacturing experience preferred
• Experience in design and release preferred
• Suspension experience preferred but not required
• Additional experience in Chassis Systems Engineering, Vehicle Integration, Manufacturing, and/or Vehicle Engineering is a plus
• Strong organizational skills and ability to manage several complex tasks simultaneously
• Ability to develop clear working-level documents and management presentations
• Experience communicating and presenting to senior leadership
• Ability and willingness to travel to Ford and supplier domestic and foreign locations
• Demonstrated supplier management, launch, and global program delivery experience
• Technical understanding and leadership experience
• Leadership skills in teamwork, prioritization, and project management
• Hands-on experience with CAD, release processes, sourcing processes, creating test requests, and documenting evidence supporting requirements and design rules
• Passion for zero defects and customer satisfaction, high energy, drive for results, and openness to learning
• Candidates must be legally authorized to work in the United States

Demonstrates expertise in Design for Six Sigma (DFSS) processes and warranty analysis to enhance automotive chassis product reliability. Proficient in CAD, project management, and cross-functional collaboration to drive quality improvements and cost reductions.

• Design For Six Sigma (DFSS)
• Warranty Analysis
• CAD Experience
• Project Management
• Supplier Management

• Reliability Engineering
• Automotive Chassis Design
• Physical Testing
• Data Analysis
• Root Cause Analysis
• Change Management
• Draft-Angle Analysis
• Undercut Detection
• Minimum Bend-Radius Validation
• Clearance Checks

• Organizational Skills
• Communication Skills
• Teamwork
• Presentation Skills
• Problem-Solving

• High Time in Service (HTIS)
• Chassis Systems Engineering
• Vehicle Integration
• Battery Electric Vehicle
• Manufacturing Processes

• CAD Software
• Warranty Tools
• Data Release Systems
• Management Presentation Tools