Dimensional Systems Variation Analysis Engineer

Ford • Dearborn, MI

97d • Hybrid

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? 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, Ford is expanding our Dimensional Systems capability with a team purpose-built to drive post-Design Freeze execution across vehicle systems during launch and current production. This group owns post-Design Freeze variation analysis encompassing all interior and exterior component and assembly design and tolerance changes, certification of checking fixtures, and the data driven management of tolerance concessions/relief and production dimensional issues in partnership with suppliers and plant teams. While you will support pre-Design Freeze activities for purchased assemblies, the primary focus of this role is post-Design Freeze readiness and execution across both purchased and inhouse engineered components and assemblies. As a Dimensional Systems Variation Analysis Engineer, you will develop and apply 3D VSA models to validate component and assembly stack-ups, optimize tooling and fixture strategies, and quantify the impact of tolerance relief and design changes on vehicle fit and function. You will support APQP/PPAP aligned dimensional deliverables through tool tryout and key build events, disposition deviations based on production data, and drive corrective actions to achieve robust launch capability. This role is hybrid/onsite as program and launch phases require, with close collaboration at Ford facilities, suppliers, and manufacturing plants. Expect travel of approximately 10-20% within North America, with increased onsite presence during tool tryout, PPAP, and key build events.

Requirements

• High School graduate or equivalent.
• 2+ years of experience performing 3D Variation Analysis using Vis-VSA or similar software in automotive applications or similar field.

Nice To Haves

• Bachelor's degree in engineering.
• Experience with SPC and statistical methods (e.g., Minitab).
• Understanding of manufacturing and assembly processes, tooling, fixtures, and plant operations.
• Experience with APQP/PPAP, DFMEA/PFMEA and control plans.
• Hands-on metrology experience (CMM, laser scanning) and MSA/Gage R&R.
• Structured problem solving (8D, DMAIC, etc.).
• ASME GDTP and/or Six Sigma certification.

Responsibilities

• Post Design Freeze Review and validate checking fixture designs for interior and exterior components/assemblies to ensure alignment with GD&T requirements.
• Ensure all significant and critical characteristics are captured and measurable in the gauge.
• Participate in digital and physical gauge certification.
• Validate downstream fit and function of proposed component design changes using 3D-VSA.
• Quantify and manage tolerance concessions across build events; assess potential impact on vehicle fit/function and align with APQP/PPAP requirements.
• Analyze internal and supplier production data to identify tolerance improvement opportunities and implement dimensional enablers for non-compliant requirements.
• Provide on-site support at suppliers and Ford plants for dimensional issues during new program launch.
• Lead cross-functional problem-solving (D&R, Manufacturing, Quality, PVT, Suppliers) to determine root cause and implement corrective actions.
• Develop assembly datum strategies and define drawing GD&T in CATIA/3DX for purchased assemblies (e.g., seat frames, cross-car beams, bumper beams).
• Define and document process flows for purchased assemblies, ensuring consistent datum schemes and feature usage across components, tooling, and assembly operations.
• Perform 3D-VSA studies (Vis-VSA) to predict system capability against appearance and functional requirements.
• Identify and recommend improvements in tooling, processing and fixture strategies.
• Correlate simulation to measurement data and refine models for accuracy.

Benefits

• Immediate medical, dental, vision and prescription drug coverage.
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up childcare 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: Entry Level
• Industry: Transportation Equipment Manufacturing
• Education Level: High school or GED