Design & Release Engineer - Body Interior

Ford • Dearborn, MI

2d • $65,100 - $166,200 • Hybrid

About The Position

Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life. We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more!
In this position...
The D&R (Design & Release) Engineer is responsible for the design, development, validation, release, and implementation of Body Interior components and systems for assigned vehicle programs. This includes leading the development of master sections and ensuring all aspects of the design contribute to manufacturing efficiency, cost optimization, quality, craftsmanship, ergonomics, serviceability and overall vehicle performance. The D&R engineer is responsible for designing parts that comply with Corporate and Legal Requirements, signing off on compliance to Engineering Requirements, ES (Engineering Specifications), DR (Design Rules), and Manufacturing, Assembly, and Service requirements. The engineer is also responsible for parts incorporation at the Assembly Plant and addressing any design, fit/finish, or assembly issues during launch.
The D&R Engineer is responsible for managing product release CAD and BOM structures, including assembly positioning and mass attribute analysis. This role also includes facilitating supplier data integration and developing CAD studies to support and drive design improvements.
The D&R Engineer is expected to understand and effectively utilize product check-in/check-out processes, version control, data release, and change management within Ford’s PLM ecosystem.
The D&R Engineer will perform feasibility analyses using CAD tools, including draft angle analysis, undercut detection, minimum bend radius validation for sheet metal, and clearance checks to support manufacturing and machining requirements.

Requirements

• Bachelor's degree in engineering or similar.
• 3+ years in Product Development, specifically in Interior Systems (Door Trim, Hard Trim, or Soft Trim or similar commodities).
• English proficiency.
• Ability to communicate and interact effectively with others including cross-functional leadership.

Nice To Haves

• Master's degree in engineering or similar.
• General knowledge of vehicle functions and specific knowledge of Interior Trim systems and components (door panels, substrates, interior trim panels, IP, etc.).
• Deep understanding of Plastic components manufacturing processes, including plastic injection molding, ultrasonic welding, heat staking, and wrapping (vinyl/leather).
• Vision and knowledge of the automotive industry environment.
• Strong 3D CAD knowledge (opening files, visualization, measurements, model transfer, etc.) and experience with CAE studies.
• Strong application of GD&T (Geometric Dimensioning and Tolerancing) and Tolerance Stack-up analysis for complex interior assemblies.
• Experience in integration with adjacent commodities (EDS/Wiring, Audio/Speakers, Mechanisms, and Sheet Metal).
• Microsoft Office management (Word, Excel, Outlook, and PowerPoint).
• Basic knowledge of materials properties.
• Basic knowledge of production processes.
• Understanding of craftsmanship, Perceived Quality, and ergonomics principles.
• Experience with Studio Development processes and appearance feasibility.
• Effective Project Management skills and effective cross-functional communication.

Responsibilities

• Comply with Program cost, weight, quality, performance, and timing targets, including meeting GPDS Program Milestone Deliverables.
• Understand and apply the GPDS (Global Product Development System) process.
• Comply with and establish/maintain Program Specific Robustness Engineering Disciplines (Quality History, P–Diagram, DFMEA, SCCAF, Boundary Diagram, Campaign Prevent, Reliability and Robustness Checklist, etc.) as required.
• Develop, lead, and maintain Program Specific ESOW (Engineering Statement of Work). Participate in the Sourcing or Re-sourcing Process (Lead To4 and To5, piece price and tooling cost reviews), and lead CPA package development to ensure all documents (including Attachment III, Eng BOM, quote assumptions, Engineering specs, Design rules, DFMEA, SC & CC list) are complete and handed off to Purchasing on time.
• Support Studio Development at all stages (K1-K6) and identify Studio Surface for high-risk Fit and Finish Issues and appearance feasibility process.
• Conduct package studies and Lead development of Master Sections, including attributes for Manufacturing, Cost, Timing, Safety, Quality, Assembly, Craftsmanship, and Ergonomics.
• Lead CAE Studies (Attachments, Robustness, etc.) and manage CAD model transfer to and from suppliers.
• Complete Engineering Design by FDJ and all Studio Surface Transfer by UPV2.
• Apply Six Sigma and 8D issue resolution methodologies, including writing deviations and non-conformance agreements.
• Lead component design reviews and follow the TDR process (Technical Design Review).
• Release parts in FEDEBOM and WERS throughout the product life cycle, utilizing FEDE/WERS as the master program BOM including key attribute data for all parts. Support the Change Control Meeting, lead interface to program change control, and write 2-pagers to request changes, obtaining all necessary information from suppliers.
• Audit and update the BOM (Bill of Material) with correct part levels and usages for prototype builds and maintain it post Job 1. This includes replacing surrogate BOM with real BOM (PS to PSC), ensuring and maintaining CAD to BOM alignment throughout the program, initial loading of final assembly part numbers from surrogate BOM (pre-PS), assigning costs to prototype build BOM, and completing VP BOM validation to ensure proper parts are ordered and all buildable combinations are correct.
• Identify validation, durability, and functional tests required as per Engineering Requirements & ES (DVP / FEDEWB). Establish and maintain Program Specific DVP, meeting all First Pass DV testing by PEC, and completing sign-off of DVP&R with all test reports uploaded by FEC.
• Resolve DPA1 through 5, support (or lead as required) the PMT process, including change management meetings and/or open issues lists (including AIMS), and develop/maintain an Open Issues list for reporting design changes, risks, and opportunities.
• Lead parts implementation/Sign-off in the assembly plant and provide assistance with quality issues at all milestones. Lead resolution of any Design, Fit/Finish, Assembly component issues during launch and provide guidance once in production.
• Review and act upon PDLs (Product Design Letters) if affected.
• Support VQR, VRTs, and PVT as required.
• Jointly with STA (Supplier Technical Assistance), provide technical assistance to suppliers through the Supplier Engagement Process and PPAP completion. Support or lead as required Component PPAP (DFMEA, PFMEA, SC/CC list, Control Plan, Supplement K, etc.) and Supplier Readiness Reviews.

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