Cell-to-Pack Technical Specialist

Ford Motor • Long Beach, CA

13d • Onsite

About The Position

We are the movers of the world and the makers of the future. We get up every day, roll up our sleeves and build a better world -- together. At Ford, we’re all a part of something bigger than ourselves. Are you ready to change the way the world moves? In this position... Ford is rapidly scaling next-generation battery manufacturing, including cell-to-pack architectures for our future electric vehicles. We are seeking a Process Engineering Technical Specialist to provide technical leadership to 100+ engineers within our battery manufacturing organization and shape the production of the next generation of electric vehicles. In this role you will serve as a critical focal point for our product development teams, ensuring the manufacturing feasibility of groundbreaking battery products and act as a catalyst for innovation between our product and technology development teams and manufacturing engineering. You will directly influence the design and implementation of cutting-edge battery manufacturing processes from early concept through pilot line, launch, and high-volume production. You will benchmark industry best practices and emerging technologies in cell-to-pack battery assembly and recommend adoption paths for Ford.

Requirements

• Bachelor’s degree in Mechanical Engineering or relevant engineering discipline.
• 8+ years experience developing new automated manufacturing processes in the battery and/or automotive industry implementing large scale projects as a Manufacturing Engineer or Project Manager.
• Demonstrated experience with:
• Developing and optimizing welding or joining processes (laser, resistance, TIG/MIG, ultrasonic, etc.).
• Metallurgical evaluation of welds (microstructure, defects, joint design considerations).
• Running structured experiments and analyzing data (DoE, regression, statistical analysis).
• Understanding or experience in cell-to-pack assembly processes (cylindrical or prismatic form factor preferred).
• Experience designing mechanical equipment, fixturing, and tooling, through use of digital tools and methods with clear understanding of tolerance stack up and GD&T.
• Must have deep knowledge and understand of assembly systems and process flow, with the ability to identify and utilize new technologies to improve manufacturing processes.
• Proficiency with engineering tools and systems such as:
• CAD tools (e.g., CATIA, NX, 3DX) for joint and fixture reviews.
• Data analysis tools (e.g., Minitab, JMP, Python, MATLAB, Excel).
• Quality tools (PFMEA, control plans, SPC, 8D, 5-Why)

Nice To Haves

• Master's degree in Mechanical Engineering or relevant engineering discipline.
• 10+ years experience developing new automated manufacturing processes in the battery and/or automotive industry implementing large scale projects as a Manufacturing Engineer or Project Manager.

Responsibilities

• Process Development & Industrialization Establish a complete battery manufacturing process, for cell-to-pack assembly system. This includes designing the production line layout and implementing all manufacturing procedures and follow through to launch at the factory.
• Drive design for manufacturing (DFM) for new cell-to-pack battery products by leading simultaneous engineering efforts with product, purchasing, and supplier teams, ensuring manufacturing feasibility.
• Develop competitive, high-ROI automation solutions by collaborating with technology partners to improve productivity.
• Collaborate with industrial engineering to define cycle time, OEE, and other key performance indicators (KPIs), and develop optimal operating and labor strategies to meet these targets.
• Develop and maintain complete documentation packages for new manufacturing processes. This includes detailed process instructions, technical drawings, preventative maintenance plans, spare parts lists, and operator training manuals.
• Proactively manage project schedules, budgets, and change requests to ensure projects are delivered on time, within budget, and to the required quality standards.
• Quality, Safety, and Compliance Lead the development of quality control methods, including PFMEA, gauge R&R studies, and inspection procedures, creating a comprehensive control plan aligned with the overall quality strategy.
• Define critical-to-quality (CTQ) characteristics, prevention/detection methods, and inspection acceptance criteria; establish inline and offline gauging strategies.
• Ensure compliance with Ford’s safety standards and industry best practices for high voltage battery manufacturing.
• Cross-Functional Collaboration Partner with cell and pack product design teams on the following:
• Influencing Design for Manufacturability (DFM) : You will provide early input to design teams, collaborating to simplify designs, optimize material selection, and reduce manufacturing complexities and costs.
• Addressing Tolerance Stack-up: You will analyze critical dimensions and tolerances, predict potential assembly issues, and recommend practical tolerances that balance design needs with manufacturing feasibility.
• Ensuring Overall Manufacturability: You will develop and validate manufacturing processes, conduct pilot runs, and provide technical support for new product launches to ensure smooth and efficient production transitions.
• Communicate effectively with team members, stakeholders, and OEM partner(s) to ensure project success and timely delivery of products.
• Support problem-solving activities (8D, 5-Why, Ishikawa) for build issues, field returns, and validation of test failures.
• Travel to domestic and international manufacturing facilities to collaborate with team members, oversee vendor runoff, and in-plant runoff.
• Launch & Continuous Improvement Support pilot builds, pre-production, and launch events at global manufacturing sites.
• Develop documentation and training for plant teams: process instructions, troubleshooting guides, maintenance best practices, and safety procedures.
• Drive continuous improvement of OEE, cycle time, yield, scrap, and consumable usage.
• Benchmark industry best practices and emerging technologies in battery cell-to-pack assembly and recommend adoption paths for Ford.

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