Program Body Leader

Ford • Dearborn, MI

1d • Hybrid

About The Position

This position is within VME-BODY AND STAMPING-USA Organization. The role will be a Body Leader – Implementation (focused position classified as Program Implementation Supervisor). This role supports major milestones from through Job 1 + Acceleration with key focus on Implementation and Launch of Tooling, Facilities and Sheetmetal Systems. The successful candidate will have minimum 7 years of experience in manufacturing demonstrating One Ford Leadership behaviors as well as extensive knowledge in key areas of Body Facility, Tooling Processm, Financial, PD and manufacturing systems. Note- This role will include travel internationally based on Program Assignments
Timing (Subject to Change):
Program Timing: Current through CY ‘29
Product / Manufacturing Development Current through CY’27
Implementation Timing: March ‘28 -> May ’29
Location(s)
Product / Manufacturing Development will be located primarily at home location in South Eastern Michigan (Product Development Center – PDC) located off Oakwood Blvd, Dearborn Mi
Tooling Design Phase will require travel to SE Michigan local Suppliers
This position is targeted for intra regional implementation at Ford Oakville Assembly Complex Plant (OAC).

Requirements

• BS, Engineering or higher
• 7-10 Years Experience in Manufacturing Engineering
• Demonstrated Leadership Behaviors, Ford Experience preferred.
• Experience in Areas of Stamping, Body Assembly and Manufacturing Tooling / Processes
• Experience working with Data and Analysis.

Nice To Haves

• MS, Engineering or Engineering Management
• 10-15+ Years Experience in Manufacturing Engineering
• Demonstrated Leadership Behaviors, Ford Experience preferred.
• Experience in Manufacturing Engineering and Operations: Areas of Stamping, Body Assembly and Manufacturing Tooling / Processes
• Experience working with Quality Departments: Blackbelt Certification.

Responsibilities

• Lead Team of Core Manufacturing Engineers in Planning / Execution phases of new model program(s)
• Accelerates process needs into overall strategy plan to support Plant requirements, integrate teams for collaboration and track open issue resolution
• Deliver Body Facility, Tooling and Quality Systems and Launch new model programs
• No safety or ergonomic red issues
• Protag process adhered to including but not limited to ECPL Placarding complete, signed-off and in place. Led and achieve Protag pink and yellow for tooling, on time and on first attempt. Ensure protag completion to support build/installation timing.
• Drive safety through weekly discussion with launch support team
• Eliminate all level 9 and 10 severity PFMEA issues
• Ensure safety and ergo sign-off at 100% Design and tooling buy-off (Assembly Ergonomic Tooling (MHS) Checklist; VOSS 1.6.3)
• Ensure no LTCR for construction and no serious injuries at all plants.
• Complete pre-task risk assessments prior to tool and facility installs.
• Resolve all ergonomics issues prior to PP.
• Assess and drive compliance for all safety and ergonomics DPA checks.
• Ensure tool designs address all safety and ergonomic issues
• Obtain signoff of ergonomics evidence book for tool buyoff
• Mandatory compliance, Manage Y(C's) including all torques and mandatory compliance designations that are released in WERS are documented in GSPAS and process accounted for
• Complete torque tracking matrix - will begin at 50% Design --> Tooling readiness, Copy of the VBS for fasteners
• Achieve 90% Flash Free Minimum in Steel Welding applications
• Ensure tooling, at 100% design & tooling buy-off, follows LD files. If changes are required, generate WLRR
• Ensure DPA checklists are correctly pulled for New Model Programs
• Drive processes, tooling and product designs to prevent deviations to GMR’s & VOSS. If unable to resolve, generate and obtain deviation approval
• Manage Hem Feasibility during DPA in conjunction with PF Development at UPV1, 2 and P-release
• Ensure weld guns and rivet guns are properly evaluated in DPA and will deliver to requirements.
• Process requirements are accurately stated in SOW
• Quality maturation plan of Process Tooling equipment will meet program objectives
• Complete all VTTO quality metrics, including tooling repeatability study
• Ensure tooling, at 100% design & tooling buy-off, follows LD files. If changes are required, generate WLRR
• PF Changes which impact design, utilize change control (i.e., generate WLRR)
• Manage, via prioritization matrix, Dimensional requirements at each build phase
• Ensure weld guns and rivet guns are properly set-up and delivering to requirements.
• Process requirements are accurately stated in GSPAS and on VBS
• No campaigns for any closure manufacturing related item
• Ensure Body Tooling Processes are meeting vehicle requirements (Pp/PpK, Surface, Sealing)
• Ensure DPA, Tooling SOW’s are released to schedule. Follow up on PO placements.
• Create and update GSPAS sheets; manage direct labor authorization for closure manufacturing
• Provide simulation inputs and optimize layout to support Total Plant Layout.
• Generate VTTO VRF for tooling buy-off requirements; reduce quantities were applicable
• Drive processes, tooling and product designs to prevent deviations to GMR’s & VOSS. If unable to resolve, generate and obtain deviation approvalVerify achievement of throughput targets for each system with Simulation Engineer
• PFMEA's reviewed, updated and delivered according to schedule (initial and final)
• Deliver tooling, facilities, and processes to achieve new product launch timing, Mfg Projects and acceleration curves in support of 100% OKTB Deliverables
• Manage VIM and Project Timeline with VIS/Launch Leader, Coordinate VTTO for buy off event
• Complete customer check sheet, tooling repeatability study & cycle time verification
• Tooling buy-off is completed, on time and on first attempt; zero exceptions and customer checklist complete; Support disposition of all 8D's and clearly document supplier agreements for OK to ship tooling & facilities
• Completion of BCE exit book at MP2 - ensure tooling meets throughput requirements (tooling achieve NET JPH for 10 shifts) via FIS
• Verify achievement of throughput targets for each sub-system using Factory Information System (or equivalent) data. If targets not achieved, 8D required to address repetitive issues significantly affecting throughput. Evidence of throughput can be obtained by reviewing the last two consecutive weeks of data (FIS if available). The average JPH (units produced/actual worked hours) produced by each subsystem and ship to paint must meet or exceed the targets established through simulation.
• Verify that all Cycle Times (with parts) for new/kitted cells or combination of cells (line) are at design intent cycle time using FIS (Report 011 - Cycletime) over 10 shifts (or equivalent) using average cycletime, per station per model. Also all stations must have no more than 10% of their overall cycles over station ERC during 10 shifts (source FIS Report 011 - Cycletime).
• FIS Validation process complete and all issues closed; reference FIS Checklist
• Manage Post Layout changes including updated 1A, validated to ensure the documentation matches the tooling on the floor.
• Support Planning with cost studies and presentations. Develop all programs within approved F&T funding levels. Meet or exceed all program budget objectives.
• Help to develop LLF's request, inputs to costing sheets, work on plan to meet targets.
• Complete all workstation cycle line layouts by .
• Drive VOME BCE/IE alignment at each study phase to ensure all direct and indirect labor (e.g. quality, weld teardown, maintenance, etc.) is captured including current state.
• Contain manufacturing-driven WERS changes to less than $250,000 and 0 labor add for total program.
• Achieve Investment Efficiency target of 1.5% for 2017 and update BOG.Formulate and estimate New Model Program layout, flexibility, cycle time, cost, facility and labor targets at required Milestones
• Review and understand SOW and supplier quotes. Look for discrepancies or non-value added costs
• Save 10% of costs, over BCE’s advance program study group
• Manage financial cost tracking and TWM for Total Program
• Reconcile supplier’s quote and work with Cost Optimization & Purchasing to negotiate costs
• Review CR’s / Q-forms for impact to closure tooling; obtain accurate cost and timing and implement change
• Cost (SOW, Supplier Selection and Financial Management):
• Write tooling SOW/APN request.
• Meet with supplier for SOW review.
• Reconcile supplier's quotes and work with Cost Optimization and Purchasing to negotiate costs.
• Initiate PN request, transfer funds in PFR and update Financial Tracking Matrix for initial purchase orders and all two-way driven amendments
• Accurately document/feedback lessons learned and update standards (GMR’s/VOSS/GPP) for continuous improvement and to prevent reoccurrence of issues
• Support team building events
• Work together with closure manufacturing and launch team(s); develop a “buddy” system with co-workers to help weekend/vacation coverage
• Complete PULSE surveys
• Provide technical and non-technical training to support employee growth and deliverables.
• Hold regular staff meetings and share department information with the teams.
• Conduct 1:1’s to ensure good communication with direct reports.
• Support all VOIE Pre-Launch planning initiatives on Labor Allocations (Direct), Develop gap to target workplan
• Complete all workstation cycle line layouts by .
• Drive VOME BCE/IE alignment at each study phase to ensure all direct and indirect labor (e.g. quality, weld teardown, maintenance, etc.) is captured including current state.
• Drive zero manufacturing-driven incremental labor increase post .
• All required GSPAS process are updated with latest revisions and sign-off. Audit process sheets to latest WERS BOM (Hard copies for stamping plants). BCE PVT to claim process sheets

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
• Number of Employees: 5,001-10,000 employees