Technical Specialist - Advanced Chassis Structural Design & Manufacturing Engineering

Ford Motor Company develops vehicles and mobility technologies focused on innovative, sustainable products. This Technical Expert position leads the design, manufacturing engineering, process development, tooling optimization, and quality validation of suspension structural components, including stampings, castings, and forgings.

Responsibilities:

• Lead the development and delivery of an in-house design and manufacturing process for suspension structural parts (stampings, castings, forgings), internalizing responsibilities
• Develop and maintain the Suspension Structural Component internal engineering foundation documents including design guides, design rules (DR’s), Requirements (RQTs), and interface contracts/agreements
• Create and manage Level 2 technical materials including Process FMEAs, Control Plans, Safe Launch Control Plans, and Sub-component BOMs
• Lead Design for Manufacturing (DFM) and Design for Assembly (DFA) feasibility reviews prior to tool kickoff, ensuring designs align with tool design specifications, plant equipment compatibility, and normal process capability limits
• Drive in-house manufacturing process simulations (e.g., stamping formability, casting solidification, forging flow) to optimize structure and ensure manufacturing process feasibility
• Lead OK to tool process with BTP supplier including approving steel purchase, OK to rough cut, and OK to finish steps
• Conduct test facility correlation study between Ford test facility (DV) to BTP supplier facility (PV) to ensure proper validation of the structure per core ES at both locations
• Develop component and assembly GD&T for in-house designs and sign-off program prints for BTP structural parts
• Support prototype development process with program teams on BTP parts
• Manage the data collection and capability analysis for Significant/Critical Characteristics (SC/CC), calculating Ppk to ensure pre-production and production capability requirements are met
• Lead demonstrable process optimization trials and Design of Experiments (DOE) to confirm manufacturing processes are optimized
• Develop comprehensive APQP plans, conduct OK-To-Build and OK-To-Ship reviews, and oversee Gauge R&R trials, including the review and sign-off of gauge and check fixture designs
• Lead root cause analysis and problem resolution (8D, JIRA ) for dimensional, processing, and manufacturing quality issues during launch, DV/PV testing, and production

Requirements:

• • BS-Engineering required
• • 10 Years of experience in chassis structural design + engineering
• • Extensive component engineering design and release experience in suspension structural components (stampings, castings, forgings), including specific experience on launch
• • Deep understanding of Build-to-Print Supplier (BTPS) deliverables and the proven ability to execute manufacturing, tooling feasibility, and PPAP requirements in-house
• • Extensive experience creating and managing DFMEA, PFMEA, SCCAF, Control Plans, and drawings with advanced GD&T
• • Experience with CAE tools, manufacturing simulation software, and process optimization methodologies (DOE)
• • Strong analytical, math, and problem-solving skills to lead root cause analysis for complex manufacturing and dimensional issues
• • Required leadership skills - quality-focused as #1 priority, innovative, excellent communicator, strong organizational skills, highly motivated self-starter
• • Ability to handle complex tasks and challenging situations under compressed timing
• • Experience communicating with senior leaders, design and release, manufacturing, and tooling suppliers
• • Outstanding planning, organizational, and project management skills with proper follow-up to accomplish multiple objectives
• • Strong One Ford Leadership Behaviors with a demonstrated ability to drive and deliver results
• • Ability to build strong effective relationships with cross-functional teams (Foundation Chassis, Design and Release, Vehicle Operations, Testing Centers, and Suppliers)
• Position requires occasional travel to assembly plants and other global chassis engineering centers to support new process development, issue resolution, and Design and Release engineer training
• Visa sponsorship is not available for this position
• Candidates for positions with Ford Motor Company must be legally authorized to work in the United States
• • Understanding of GPDS deliverables and basic Ford engineering tools including Teamcenter, WERS, and buck environments