Product Development Engineer - Exterior Lighting Vision Systems

Ford Motor • Dearborn, MI

3d • $68,300 - $192,900 • Hybrid

About The Position

The Exterior Lighting Engineer is a multi-disciplinary technical authority responsible for the integrity, evolution, and in-house design ownership of lighting systems. As the department shifts toward Build-to-Print (BTP) models and AI-driven engineering, this role is the primary driver of Ford’s internal technical foundation. This position bridges the gap between mechanical, electrical, software, and optical engineering. Whether focused on advanced development or application execution, the engineer is the primary lead in ensuring that lighting technologies are not only robust and manufacturable but also developed using the most advanced digital transformation tools available.

Requirements

• Bachelor’s degree or higher in mechanical engineering or a related field.
• 5+ years of experience in design, development, or launch of automotive lighting or similar components.
• CAD Capable (such as CATIA, 3DX, Teamcenter) & familiarity with CAE tools and software.
• Benchmarking experience.
• Integration and developing CAD studies to support and drive design improvements.
• Demonstrated ability to manage multiple issues effectively and efficiently.
• Demonstrated ability to show initiative and prioritize workload.
• Ability to travel domestical and international.
• Proficient in MS Office apps such as Excel, Word, Power Point MS Teams, and MS Azure SharePoint.

Nice To Haves

• Master's of Science in Engineering (Mechanical preferred).
• 7+ years of experience.
• Experience in design and release of Exterior Lighting.
• Software literacy and mechatronics experience.
• Strong understanding of statistical analysis.
• 8D and 5Why corrective action and problem-solving skills.
• Experience with DFMEA's, PFMEA's, and SCCAF's.
• Detailed understanding of materials, manufacturing technologies, and GD&T.
• Ability to work in a fluid environment when overall vehicle targets, size, appearance, and manufacturing location are not always known.
• Ability to solve complex system issues and deal with a variety of concrete variables in situations where only limited standardization exists.
• Effective oral and written communication skills.
• Ability to adapt your role to a variety of applications and issues as required.

Responsibilities

• Leading the transition from supplier-led designs to Ford-owned "Build-to-Print" applications, including developing detailed internal CAD, optical models, and technical data packages.
• Utilizing and developing Artificial Intelligence to automate administrative and data-heavy tasks, and leveraging AI Generative design tools to optimize optical performance, thermal management, and structural integrity.
• Defining and maintaining the technical specifications and global design rules that govern all lighting programs.
• Driving the research and development of next-generation lighting technologies (e.g., advanced LEDs, ADB/Matrix, laser, or OLED systems).
• Serving as the technical lead for global compliance (FMVSS 108, ECE, etc.).
• Leading the proactive identification of risks through the development and ownership of DFMEA (Design Failure Mode and Effects Analysis) and supporting PFMEA (Process Failure Mode and Effects Analysis).
• Serving as the lead investigator for complex system failures, requiring physical teardowns, forensic analysis of field returns, and engineering of technical countermeasures.
• Owning the technical "health" of the commodity, impacting quality metrics and warranty spend.
• Identifying and executing technical cost-reduction strategies through BTP efficiencies.
• Leading the negotiation between Studio’s aesthetic vision, manufacturing feasibility, and purchasing targets.
• Acting as the technical authority during early-stage feasibility (Pre-PS) to ensure alignment between aesthetic vision and engineering requirements.
• Collaborating with cross-functional teams to deliver a robust system at vehicle level, ensuring all system interfaces of Lighting components are evaluated and validated.
• Creating and presenting technical presentations for peer and management reviews.
• Performing and/or reviewing & signing off technical analyses of component/system functional and packaging studies such as: dimensional stackups (GD&T layouts), CAE’s, dynamic calculations and simulations.
• Actively participating in the Technical Design Reviews.
• Reviewing and signing off CAD in Teamcenter.
• Developing Lighting System documents including DFMEAs, SCCAF, Boundary Diagrams, P-Diagrams, & DVP&Rs.
• Leading design reviews based on Failure Mode Avoidance.
• Developing ESOW (Engineering Statement of Work), EC (Engineering concepts) and participating in the sourcing Process (SOBA, ED&T review, piece cost and tooling cost review.
• Identifying validation, durability and functional tests required as per SDS & ES. (DVP / FEDE).
• Addressing issues with root cause analysis (8Ds, 3x5Why) and permanent corrective actions implementation.
• Applying knowledge of six sigma principles.
• Collaborating with STA with technical assistance through the Supplier Engagement Process.
• Delivering by applying the One Ford Behaviors.
• Traveling to supplier manufacturing and testing sites when required.
• Traveling to North America plants when required.

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