STA Site Engineer

Ford • Dearborn, MI

8d • $84,480 - $162,120 • Onsite

About The Position

We are looking for an experienced candidate to join our STA organization with effective communication, technical knowledge, project management, manufacturing, and process quality expertise in component parts production for Body Interior commodities. As a Supplier Technical Assistance (STA) engineer specializing in Interiors, you will be responsible for industrializing and managing "Quality" and "Capacity" of interior commodities at Tier 1 supplier sites — including injection molding, Blow molding, low-pressure molding, thermoforming, and final assembly operations — on new model program launches and in-series production. The Site STA – Interiors is responsible to lead and collaborate within Ford and multiple supplier partners to launch Interior commodities — including seats, instrument panels (IP), door trim, headliners, carpet/flooring, console modules, interior trim/garnish, and soft-touch/foam components — for Battery Electric Vehicles (BEV) and Internal Combustion Engine (ICE) vehicles. The candidate will be responsible for industrializing and managing Quality, Capacity, and resolving production delivery issues for new model program launches and "in-series" production programs.

Requirements

• Bachelor of Science/ Engineering, or academic equivalent
• Knowledge of manufacturing process(es) of interior commodities (Injection Molding, Blow Molding & Assembly processes for Doors, Consoles, Hard trim, IPs, Ducts & Headliners).
• Good understanding of Capacity Management of Interior commodities mentioned above.
• Knowledge of Problem Solving, Quality systems and tools.
• Ability to travel up to 75% of the time with increased travel required during program launches

Nice To Haves

• Advanced knowledge of the electronics manufacturing process with hands-on experience
• Six Sigma Black Belt Certification: Demonstrated ability to lead quality improvements initiatives, apply Six Sigma philosophies and principles (including the DMAIC Model)
• Conducted Statistical Analysis and mentored other engineers
• Experience mentoring internal teams of Supplier Quality Engineers
• Experience Industrializing NEW Automotive Electronics Manufacturing suppliers in North America (Greenfield Sites) leading to on-time PPAP approval.
• Experience in Ford's Phased PPAP and APQP Process and Deliverables
• Experience using AI in problem solving cases

Responsibilities

• Drive Flawless Launches at assigned supplier sites, collaborating with Launch STA team (Ex: Schedule A, PPAP (Production Part Approval Process), Supplier Quality Issues resolution). Escalate significant issues promptly and ‘date to green’ plan to appropriate management
• Conduct onsite evaluation visits for Priority commodities as per GPDS supplier engagement process for new programs
• Support capacity studies interfacing with suppliers and Ford cross-functional teams
• Review supplier incremental tooling work plans compliance to PPAP (Production Part Approval Process) requirements
• Drive capacity/uplift actions implementation with suppliers inline with the GCP study requirements
• Drive Supplier Process capacity issues resolution as needed – Production constraint risk mitigation working with Ford and Supplier teams and manage “date to green” plan
• Monitor supply status of 24/7 roster suppliers and Blue bar status of PPAPs beyond implementation timing
• Review supplier Capacity Analysis Reports (CAR) for compliance to capacity requirements
• Drive robust Supplier Failure Mode Avoidance through PFMEA, SCCAF, CP reviews, Manufacturing feasibility reviews and Health chart deployment as applicable
• Drive Supplier manufacturing health chart compliance and support development of new health charts
• Drive suppliers for Special process compliance with the support of STA Technical Specialists
• Drive continuous improvement in manufacturing excellence with the assigned sites through Q1-MSA deployment, Q1 attainment/ retention, Health chart deployment, Supplier training as required.
• Drive deployment & improvement of Quality performance requirements (Q1, QR, TGW, R/1000, CPU), through Reduction, Benchmarking, Lean Manufacturing, G8D (Global 8 Disciplines) methodology, PFMEA (Process Failure Mode Effect Analysis), SPC (Statistical Process Control), Gage R&R (Repeatability and Reproducibility), Gage R&R (Repeatability and Reproducibility), etc.) as required
• Drive new supplier site evaluations and Supplier Risk Assessment on new sourcing in support of GCST, identifying Risk Mitigation.
• Drive closure of supplier process Quality issues related to Stop Ship/Build, BSAQ (Balanced Single Agenda for Quality) projects and Field Action Stop Ship/Prevent Action
• Drive compliance to all organizational and corporate training requirements and SIM process compliance.

Benefits

• Immediate medical, dental, and prescription drug coverage
• Flexible family care, parental leave, new parent ramp-up programs, subsidized back-up childcare 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