Program Body Vehicle Line Specialist

Ford • Dearborn, MI

1d • Hybrid

About The Position

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 Facility, Tooling and Quality Systems and Launch new model programs

Requirements

• BS, Engineering or higher
• 5+ Years Experience in Manufacturing Engineering
• Demonstrated Leadership Behaviors
• Experience in Areas of Stamping, Body Assembly and Exterior Ornamentation
• 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

• Review Master Sections
• Support feasibility reviews
• Provide Cross Carline Experience to implement Lessons learned and adhere to best common practice guidelines
• Assist in defining new program assumptions and achieve best in world quality based on prior vehicle experience
• Ensure GAP/ Best Practices / GMR / Design Rules / PDPD / CETP's are followed.
• Power Wall / Clay Reviews verify fit and finish match SRI targets and requirements
• Ensure that product design is robust and will prevent misbuilds, misloads, or other manufacturing issues ensuring that engineering line rates can be achieved. Identify and develop action to prevent knifing or shingling conditions.
• Ensure Locator commonality and part orientation through gages tools etc. – including outside part suppliers
• Support Virtual Formability studies ensure stamping parts are manufacturable.
• Predict and Establish Measuring points and tolerances using DVA, LD standards and Engineering Judgement.
• Structures approval digitally and physically signoff designs and EI changes.
• Design Compatability reviews.
• Review Interface with trim, Chassis ensure Bodyshop requirements are deliverable or drive modifications to Trim / Chassis components to ensure they are less sensitive to Sheetmetal variation.
• Cut sections to release product to verify Weld feasibility, fit / finish, cheats, metal thickness, clearances and flat for sealer, weld flange length, weld gun access, slip planes, interferences, product and process compatibility cheats.
• Review Component and assy design with suppliers
• Assist in development / use of Data Control Model (DCN) and adjustable craftsmanship models.
• Order parts and follow up for PCF
• Ensure all diagnostic gages follow build process.
• Ensure Sensitivity analysis is performed on areas of concern and that recommendations are accepted.
• Development of all dimensional control plans in bodyshop (Labor/cmm/capacity etc.)
• Lead layout of CMM and Dimensional Control areas.
• Assist in the development of Quality Roadmaps (TGW, R/100 and warranty reduction plans)
• Monitor product quality indicators and assure that appropriate actions are incorporated into the new model.
• Verify that product design meets standards for Margin and Flushness (flushness of one line in side view, minimized skewed cutlines, overcrowns, door cheats, hood cheats, laserwelding cheats, Nose to Fender cheats)
• Review Cube and snapshot models (white room) for craftsmanship items to ensure "Best in world" delivery of exterior with all anticipated variances.
• Ensure issues identified in FC Reviews are monitored and driven to resolution.
• Verify Design compatibility between all sheetmetal components, assist in the design compatibility of other components that interface to sheetmetal. (Chassis, Trim)
• Act as the manufacturing and assembly representative in all structures reviews providing feedback on preferred designs.
• Lead the Measuring Point selection process to assure adequate dimensional information is taken and to assure measuring points are coordinated between adjacent panels and support needed diagnostic for trim / Chassis and ext ornamentation.
• Ensure that assembly plant layout and pullout stations are adequate to support a solid dimension control inspection frequency.
• Ensure that Scheduling is given PCF Vehicle specs and that the units are scheduled
• Ensure that PPM is delivered the PCF1 and 2 BOM and that the BOM is validated for all columns (production supplier, quanitity, part etc) utilizing the How to pull your own GPIRS BOM presentation.
• Responsible to ensure the accuracy of the DCD costing for assigned program.
• Support and Lead LD meetings with respective Manufacturing Engineer for assigned program.
• Support and Lead MP Drawings meetings with respective Manufacturing Engineer for assigned program
• Approve gage / fixture design concept and 100% design meetings and sign off all fixtures.
• Update PCF executive summary on weekly basis.
• Review all DCD Program Scoping documents to ensure scope is sufficient to meet demands of the program and are optimized for cost and quality.
• Develop the Pre – Launch Control Plan ensuring the frequencies and sub assemblies to be checked are adequate to support the bodyshop proforma and deliver a best in world vehicle.
• Assist the Dimensional Control Engineer with creating the production control plan and ensure that frequencies and checks are adequate to ensure Best in World Delivery for ongoing production. Coordinate the approval of said process through the Dimensional Control Dept Manager for signoff.
• Ensure Locator consistency through tools and gages
• Ensure Design rules, GMR, SDS, PDPD compliance.
• Utilize Pre-TT build events (DCV or VP/CP) to schedule and execute an effective Emphasis build.
• Ensure that all products will deliver Best in World attributes (Wind / Water leaks / Air Leakage / Fit / Function / Efforts )
• Perform simple RSS studies and validating and work with DVA for more complicated geometrical studies – ensure that ongoing normal variability will not effect SRI, Manufacturability, downstream customer concerns, wind/water etc...
• Support final assembly by Reviewing the GD&T assumptions and gage assumptions on exterior ornamentation to ensure strategy replicates how the parts see the vehicle and ensure that they will deliver best in world Fit and Function.
• Provide the Voice of the Customer for sheetmetal related items and key interfacing areas.
• Support all Virtual Builds and DPA Events.
• Support all feasibility discussions
• Ensure Fit and Finish through SRI Development.
• Ensure Carryover part issues build issues and capability issues that may affect the new model launch are corrected or addressed or have established workplans to resolve.
• Ensure that PCF metal is ordered correctly and on time.
• Validate PCF BOM and work with PPM to correct as required.
• Support the Bodyleader by managing the VTTO requirements and ensuring that the Pilot Plant and suppliers deliver material as promised and have the builds scheduled on their master schedule.
• Lead Manufacturing Driven product feasibility rejections
• Ensure Design gaps and slip planes are properly engineered
• Ensure product meets are MDS, SDS, PDPD, DPA Checklists.
• Ensure Product meets all welding requirements and drive resolutions (Flange lengths, joint designs, gun clearance, thickness ratio's, etc)
• Participate in DFMEA/PFMEA meetings
• Participate in Tooling Design reviews
• Signoff and Ensure all Supplier gages follow recommended practices, have no RFS pins, and are adequate to ensure that only quality supplier parts will be shipped to Ford Motor Company
• Work with STA/Purchasing to ensure supply base will support Ford Motor Company (Quality, Throughput, Cost, Timing)
• Determine Capabilities of Assembly plant layout and inspection personnel and work with Plant personnel to develop training plans to improve their capabilities. Drive the implementation of that training plan and get frequent status reports from Plant.
• Determine Needs of the Assembly Plant Layout and inspection department and ensure deficiencies are addressed prior to launch phase. (equipment, headcount, facility, tooling, training)

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