CAE Manufacturing Engineer

Ford Global Career Site • Dearborn, MI

5d • Hybrid

About The Position

As part of our Manufacturing team, you’ll help build the world-class, state-of-the-art smart vehicles we're known for. In our plants around the world, we’re constantly developing new technologies and processes to further increase our efficiency. You'll get the satisfaction of making great products people use and love.
In this role, the CAE Manufacturing Engineer will work with Powertrain Manufacturing, Product Development, and Suppliers, to successfully develop and launch next-generation Powertrain processes. Successful candidates will have a proven record of working with cross functional teams in the development and implementation of complex machining and assembly solutions.
The CAE Manufacturing Engineer will be required to apply their knowledge of Finite Element Analysis methods as it applies to both internal combustion engine and Emotor manufacturing for both machining and assembly operations. In this role, the CAE engineer will have direct impact over the design and processing of powertrain components in current and future Ford products. Ideal candidates must navigate and drive change in a complex internal environment, challenging the status quo as we define an all-new way of manufacturing vehicles.
Drive the CAE process modelling requests enabling a framework for the cross functional teams to create robust machining and assembly processes. Conduct analysis, provide interpretation, communicate, and document simulation results. Ensure manufacturing feasibility for assembly and machining process designs, resulting in parts that can be machined or assembled by standard and best practice methods in support of new Powertrain program product launches.

Requirements

• Bachelor of Science/Engineering; MBA/MS preferred - Chemical/Electrical/Mechanical or Metallurgy/Materials Science.
• 5+ years prior experience with Machining CAE, preferably for powertrain applications.
• Strong communication skills, both written and oral.
• Working level knowledge of Assembly Operations.
• Machining fundamentals and process understanding of common machining operations including turning, boring, milling, drilling, reaming, grinding
• Knowledge of linear, elastic, and plastic deformation and analysis methods
• Working level knowledge of tooling, work holding, and fixturing.
• Knowledge of powertrain materials, steel, cast iron, CGI, and aluminium alloys.
• Understanding of finite element analysis including simulation software; SimCenter, Altair, NASTRAN, Abaqus, Jupiter, Thirdwave systems, and MATLAB.
• Excellent problem-solving skills and the ability to make decisions in a fast paced, dynamic environment.
• Exceptional communication and interpersonal skills to present, persuade, and collaborate at all levels of the organization.
• Highly motivated self-starter capable of driving change and influencing engineering decisions, with or without authority.
• Proven track record of delivering major product launches in an automotive manufacturing facility.
• Ability to work in a production setting and aid in troubleshooting of supplier equipment and processes. Possess practical problem-solving skill and the ability to address a variety of variables in situations where only limited standardization exists.
• Ability to travel both domestically and internationally.
• Travel may be required from 25% - up to 40% of time.

Nice To Haves

• MBA/MS preferred - Chemical/Electrical/Mechanical or Metallurgy/Materials Science.

Responsibilities

• Provide technical support to Product Development (PD) Component Program Module Teams (CPMT's) and coordinate process design between Product Engineering, PTME – Machining and Assembly, and external machining suppliers to assure ‘design for manufacturing feasibility’ of new Powertrain Machining and Assembly Methods.
• Support the Digital Preassembly 5 (DPA5) process through the development of component Manufacturing Design Specifications (MDS) and Manufacturing Process Specifications (MPS). Complete Manufacturing Assessments.
• Support simultaneous engineering and feasibility engineering studies among product engineering, manufacturing engineering, and supplier organizations.
• Support supplier selection evaluation process through manufacturing assessments and assist Purchasing in the evaluation, development, and selection of suppliers and subcontractors.
• Conduct clamping deformation analysis and communicate results to fixture supplier, driving robust fixture design.
• Support Machining Process engineers for natural frequency vs. cutting frequency analysis, face milling analysis, cylinder bore boring roundness analysis, valve seat machining deformation, flat and cylindrical surface stiffness, dynamic stiffness analysis, face milling force and burr prediction.
• Support assembly process engineers with press in analysis requests for valve seat and guide, axle tube, gear and bearing. Conduct bolt mounting deformation analysis, contact simulation, and staking analysis for applicable components.
• Evaluate innovative and disruptive emerging processes and material technologies for potential application to Ford products.
• Support Product Engineering in the selection and specification of component materials and test procedures.
• Assist Ford manufacturing plants, as required, in resolving significant engineering issues and achieving continuous improvement for both new programs and current production.
• Provide technical support, as required, to Purchasing (Component Buyers and Supplier Technical Assistance) involving the resolution of machining and assembly methods related to productivity and quality issues of external suppliers.

Benefits

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Number of Employees: 5,001-10,000 employees