Product Development Engineer-Brake Core NVH and Dynamometers

Ford Motor • Livonia, MI

7h • Hybrid

About The Position

The Brake NVH Core Engineer is a technical and operational leadership role in Underbody Systems. The engineer owns brake noise, vibration, and harshness (NVH) methods and requirements, applies model-based systems engineering to connect customer needs with design decisions and verification evidence, serves as the technical lead with CAE, and leads a peer network of brake NVH champions. The role also supports program-level NVH activities, including dynamometer noise signoff, cold-room and low-frequency vehicle testing, electric parking brake (EPB) sound quality, and vehicle-level subjective and objective evaluation.

The position is the single point of ownership for brake dynamometer testing across Ford-operated and leased facilities. It determines test assignments and schedules based on machine capabilities, manages competing program priorities, and oversees an annual operating budget in the millions of dollars. The role coordinates Ford engineering, facilities, skilled trades, test-lab operators, and suppliers, and is accountable for test capacity, reliability, upgrades, spending, and clear communication of decisions and results. The work directly affects program timing, launch quality, warranty performance, and customer satisfaction. The position is hybrid and requires onsite work four or more days per week.

Requirements

• Bachelor's degree in Mechanical, Automotive, Aerospace, or a related engineering field.
• At least 5 years of experience in brake NVH, brake system engineering, or brake dynamometer testing.
• Ability to prioritize competing demands, make decisions under pressure, and influence without direct authority.
• Strong communication, negotiation, and relationship-building skills across engineering, trades, suppliers, and management.
• Financial skills in budget tracking, forecasting, and detailed invoice review.
• Willingness to be available for urgent issues outside normal hours.
• Professional proficiency in English and Spanish.

Nice To Haves

• Master's degree in Mechanical, Automotive, Aerospace, or a related engineering field.
• Hands-on experience executing and interpreting dynamometer or vehicle-level tests.
• Experience managing a laboratory or test facility, including scheduling, calibration, uptime metrics, and vendor oversight.
• Familiarity with dynamometer systems, including environmental control, drive systems, and control software such as LabLINK, RevData, and ProLINK.
• Knowledge of EMB, EPB, and 48V brake systems and their test requirements.
• Working knowledge of CAE and model-to-test correlation.
• Experience writing technical requirements and applying systems engineering practices.
• Experience with model-based systems engineering tools.
• Experience leading technical networks, training others, or managing contracted test providers.
• Experience supporting vehicle launch and warranty-reduction activities.
• CAD Level 2 capability, if applicable to this grade.

Responsibilities

• Develop, document, and maintain brake NVH test and analysis methods, translating analytical and physical learnings into design guidance and reusable standards.
• Author and maintain system and component NVH requirements, using model-based systems engineering to maintain traceability from customer needs through CAE, test methods, and verification evidence.
• Serve as the key technical lead with CAE, align modeling priorities, and drive model-to-test correlation.
• Lead the peer network of brake NVH champions by providing coaching, common methods, escalation support, and cross-program alignment.
• Define dynamometer and vehicle-level test strategies; interpret acoustic, vibration, thermal, and dynamometer data; and support supplier signoff testing.
• Support program NVH deliverables, including dynamometer noise signoff, cold-room and low-frequency noise vehicle tests, EPB sound quality, and low-speed vehicle tests.
• Lead root-cause investigations of squeal, judder, roughness, moan, and groan, confirm corrective actions under representative conditions, and explain differences between Ford and supplier test results.
• Receive and reconcile all dynamometer test requests and lead the weekly scheduling meeting, reviewing machine status, fixture builds, parts, and supplier signoffs.
• Assign tests to suitable dynamometers based on machine capability and maximize total capacity by using simpler machines where appropriate.
• Schedule tests only after parts arrive and signoff photos are approved; prioritize competing program demands and communicate decisions to stakeholders.
• Act as the escalation point for dynamometer problems, including breakdowns, malfunctions, late reports, missed supplier signoffs, and urgent test starts; plan holiday coverage and coordinate fixture and part movements between buildings.
• Manage the annual dynamometer operating budget, authorize normal operations spending, forecast monthly spend and burn rate, and determine the number of leased dynamometers to fund based on workload and availability.
• Audit monthly operating invoices, resolve discrepancies with the lab operator, and recommend payment after checking charges for testing, fixture builds, script updates, canceled tests, and software development.
• Schedule and approve dynamometer and capacitance-probe rack calibrations; approve fixture and driver builds; order spare hardware; provide workload inputs for the annual budget; and work with facilities leadership to prioritize repairs and upgrades.
• Run biweekly operations efficiency reviews, update metrics and run charts, review breakdowns and repairs, track downtime and uptime against commitments, identify hidden capacity losses, and monitor report-generation timing.
• Monitor recurring failures in environmental control units, refrigerant systems, cooling-water systems, and main drive systems, and promote effective preventive maintenance.
• Establish oversight for the leased-facility vehicle chassis dynamometer, track uptime and root causes, and evaluate long-term options such as a new chassis dynamometer with EMB capability.
• Lead dynamometer upgrade planning, obtain quotes, define scope and funding, and drive projects such as EMB-compatible noise scripts, servo control updates, higher-voltage and higher-amperage power supplies, and EMB updates to the highest-inertia dynamometer.
• Secure replacement corrosion-chamber capability as existing facilities are retired and coordinate upgrades across engineering, facilities, skilled trades, lab operators, and software specialists.
• Audit, enforce, and update operating procedures, including test-request flow, supplier signoff guidelines, and pre-test setup checks; maintain fixture inventory, storage and scrapping guidelines, and post-test part retention processes.
• Host professional laboratory tours for audiences ranging from interns to executives.
• Manage working relationships among Ford engineering, facilities, skilled trades, contracted lab operators and software specialists, and the chassis-dynamometer lab; escalate repairs and upgrades through appropriate channels.
• Communicate test status, risks, and results clearly to technical and leadership audiences.
• Be available outside normal hours when needed and plan holiday lab coverage.

Benefits

• Immediate medical, dental, vision, and prescription drug coverage.
• Paid parental leave, new parent ramp-up programs, and subsidized back-up childcare.
• Adoption and surrogacy expense reimbursement, fertility treatments, and other family-building benefits.
• Vehicle discount program for employees and family members, and management leases.
• Tuition assistance.
• Employee resource groups.
• Paid time off for individual and team community service.
• Vacation time, sick/personal time, and paid holidays, including between Christmas Eve and New Year’s Day.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level