ICE Powertrain & Thermal Systems Engineering (IPTSE) Quality/Design Release Engineer – High Time In Service (HTIS) Reliability

Ford • Dearborn, MI

12h • Hybrid

About The Position

The Quality/Design Release Engineer position focuses on issues with the engine and thermal systems that manifest later in product life. The role requires utilizing best practice problem solving to quickly determine root cause, develop strategies and tools to catch issues sooner, develop new designs and execute test plans that ensure such issues are averted in the future and support efficient and robust service solutions. The specific areas / sub-systems of responsibility would be within the base engine / long block and would be defined at the point of employment and joining the base engine team based on the successful candidate’s skill set and experience coupled with the skill set of the existing team. Examples of the ‘base engine’ / long block sub-systems are; Cylinder Block, heads, PCV, EGR, Sealing, Covers, Valvetrain, VCT’s, Cam Drive, Piston and Rod, Rotating system, Oil pump & Lubrication, Engine bearings Etc. 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 of Science Degree in ME/EE/Material Science/Aerospace Engineering.
• 2+ years of experience leading projects.
• 2+ years of experience with internal combustion engines or after-treatment systems in one or more of the following areas: Design, Test, Controls, Calibration.

Nice To Haves

• 6-Sigma green belt, black belt and Design for Six Sigma experience a plus.
• Familiarity/experience with Strategic Problem Solving.
• Familiarity/experience with Failure Mode Avoidance and Robustness and Reliability processes.
• Familiarity with quality tools.
• Knowledge of key engine/powertrain subsystems including base engine, cooling, airpath, fuel, after-treatment, etc.
• Strong project management, problem solving and organization skills.
• Excellent teamwork and communication skills.
• Self-starter with the ability to manage multiple work streams simultaneously.
• Enjoys taking on new challenges, embraces learning and discovery.

Responsibilities

• Lead/support High Time in Service Quality Projects using Design for Six Sigma / 8D processes on aggressive timelines to support IPTSE’s warranty spend and failure rate reduction targets.
• Responsibilities include evaluation of high warranty spend/failure rate subsystems and engine/vehicle applications with a focus on issues that contribute to > 12 MIS warranty and/or are design/physics related versus supplier quality/manufacturing defect related.
• Projects will be expected to rapidly work through the Define, Characterize, Optimize and Verify phases of the DFSS process including root cause identification and verification, implementation of corrective actions, and prevent recurrence.
• Ability to design, execute or coordinate analytical and physical testing from component bench level to full powertrain/vehicle testing to identify root cause, replicate quality issues and validate fixes.
• Identify and document lessons learned for knowledge preservation.
• Lead new/forward model product development of the base engine sub system for new engine platforms.
• Design, develop, and release components.
• Lead/Support resolution of major design, manufacturing, program, and launch issues as they arise.
• Create, complete, and approve supplier and Ford engine DVPs and oversee testing in support of robust validation.
• Lead Sub System CPMT activities.
• Support all program meetings (EPMT, Design Review, DPMT, change control, etc.).
• Lead drawing release and changes.
• Interface with Calibration, mating components, Purchasing, suppliers, and mfg/assembly plants.
• Prototype Build coordination: load forward model part numbers into system and ensure fit and function.
• Work directly with suppliers, Supplier Technical Assistance (STA), and launch teams to support programs and resolve quality issues, included travel both domestic and international when required.
• WERS (Worldwide engineering release system) coordination; alerts, concerns and notice processing.
• Develop and maintain CPMT documents, including appropriate quality documents (ESOW, DFMEA, PTDV, e3P, SCCAF’s, Global Integrator, PPAP & PSW’s, 543 Chart etc.) for program specific sub-system responsibilities.

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