STA Site Engineer

Ford•Dearborn, MI

2d•Hybrid

About The Position

Implement commodity-specific business plans to ensure your suppliers exceed all corporate launch, quality, capacity, warranty metrics, and vehicle delivery Implement actions to ensure zero vehicle losses from suppliers Conduct Launch Readiness Reviews at Supplier sites as per Ford's Supplier Engagement Process for future model programs Conduct Manufacturing Site Assessments (MSA), identifying gaps, and establishing/monitoring CIAP's (Continuous Improvement Action Plans) Conduct onsite evaluation visits for Priority commodities as per GPDS supplier engagement process for new programs Support Capacity Purchasing Team by interfacing with Suppliers and Ford Cross Functional Team members Drive capacity/uplift actions with Suppliers in accordance with Global Capacity Planning (GCP) and Manufacturing Capacity Planning Volumes (MCPV) study requirements Drive/Support Supplier Process capacity issue resolution. Work with Ford and Supplier teams to manage “Date To Green (DTG)” plan(s) Review and approve Supplier Capacity Analysis Reports (CAR) ensuring compliance to capacity requirements Review supplier incremental tooling work plans ensuring that plans comply to PPAP (Production Part Approval Process) requirements Review and approve PPAP's (Production Part Approval Process) for engineering changes, supplier driven (SREA) changes, and new tooled end items Drive on-time PPAP submissions ensuring that supplier project timing plans are on track Monitor supply status of 24/7 suppliers. Monitor PPAP's that go beyond program timing using Ford recommended tools (ex. Blue Bar/Rate of Climb Charts) Promptly escalate significant constraints (ex: quality/launch) issues to the appropriate management levels Drive robust Supplier Failure Mode Avoidance by Deep Diving: DFMEA's/PFMEA's Special Characteristics Agreements (SCCAF) Control Plans Manufacturing Feasibility Drive Supplier manufacturing “Process Standards” (Health Charts) compliance and support development of new process standards Drive Supplier “Manufacturing Process Audits” (Special Processes) compliance utilizing STA Technical Specialists when needed Drive continuous improvement in manufacturing excellence through Q1 MSA deployment, Q1 attainment / retention, Health Chart deployment, and Supplier training as required. Drive deployment & improvement of Quality performance requirements (Q1, Quality Rejects, Warranty Metrics - R/1000, CPU, TGWs), through Q1 MSA, Warranty Reduction, Benchmarking, Lean Mfg., G8D (Global 8 Disciplines) methodology, PFMEA, SPC (Statistical Process Control), Gage R&R (Repeatability and Reproducibility), etc., as required Drive new Supplier Site Evaluations and Supplier Risk Assessment on new sourcing in support of Global Council Steering Teams, identifying Risk Mitigation. Drive closure of Supplier process Quality issues related to Stop Ship Builds, Field Service Actions, and BSAQ (Balanced Single Agenda for Quality) warranty projects. Drive compliance to all organizational and corporate training requirements Frequent Travel within NA, MX and/or Canada, depending on assigned supplier site locations Established and active employee resource groups

Requirements

Bachelor of Science/ Engineering, or academic equivalent.
Be proficient in English, both written and oral, when working with global teams
Knowledge of manufacturing process(es) of the responsible component commodities.
Commodity experience in Steering and Automated/Manual Assembly Processes.
Ability to develop and present materials to leadership on short notice.
Ability to lead resolution of manufacturing, quality, and/or capacity issues on-site with suppliers.
Ability to travel in the US, Canada, and Mexico approximately 75% of the time.
Knowledge of Problem-Solving tools and Quality Systems (ex. IATF) and Quality tools
Experience leading multiple assignments with demanding timelines
5+ years' experience in one or more, but not limited to the following manufacturing process: Casting, Machining, Forging, Stamping, Welding, Plastic/Rubber Molding, Brazing, Sintering, Automated/Manual Assembly Processes, Controls Automation programming, Paint, Chroming, SMC, Manufacturing, maintenance, and quality operations experience

Responsibilities

Implement commodity-specific business plans to ensure your suppliers exceed all corporate launch, quality, capacity, warranty metrics, and vehicle delivery
Implement actions to ensure zero vehicle losses from suppliers
Conduct Launch Readiness Reviews at Supplier sites as per Ford's Supplier Engagement Process for future model programs
Conduct Manufacturing Site Assessments (MSA), identifying gaps, and establishing/monitoring CIAP's (Continuous Improvement Action Plans)
Conduct onsite evaluation visits for Priority commodities as per GPDS supplier engagement process for new programs
Support Capacity Purchasing Team by interfacing with Suppliers and Ford Cross Functional Team members
Drive capacity/uplift actions with Suppliers in accordance with Global Capacity Planning (GCP) and Manufacturing Capacity Planning Volumes (MCPV) study requirements
Drive/Support Supplier Process capacity issue resolution.
Work with Ford and Supplier teams to manage “Date To Green (DTG)” plan(s)
Review and approve Supplier Capacity Analysis Reports (CAR) ensuring compliance to capacity requirements
Review supplier incremental tooling work plans ensuring that plans comply to PPAP (Production Part Approval Process) requirements
Review and approve PPAP's (Production Part Approval Process) for engineering changes, supplier driven (SREA) changes, and new tooled end items
Drive on-time PPAP submissions ensuring that supplier project timing plans are on track
Monitor supply status of 24/7 suppliers.
Monitor PPAP's that go beyond program timing using Ford recommended tools (ex. Blue Bar/Rate of Climb Charts)
Promptly escalate significant constraints (ex: quality/launch) issues to the appropriate management levels
Drive robust Supplier Failure Mode Avoidance by Deep Diving: DFMEA's/PFMEA's Special Characteristics Agreements (SCCAF) Control Plans Manufacturing Feasibility
Drive Supplier manufacturing “Process Standards” (Health Charts) compliance and support development of new process standards
Drive Supplier “Manufacturing Process Audits” (Special Processes) compliance utilizing STA Technical Specialists when needed
Drive continuous improvement in manufacturing excellence through Q1 MSA deployment, Q1 attainment / retention, Health Chart deployment, and Supplier training as required.
Drive deployment & improvement of Quality performance requirements (Q1, Quality Rejects, Warranty Metrics - R/1000, CPU, TGWs), through Q1 MSA, Warranty Reduction, Benchmarking, Lean Mfg., G8D (Global 8 Disciplines) methodology, PFMEA, SPC (Statistical Process Control), Gage R&R (Repeatability and Reproducibility), etc., as required
Drive new Supplier Site Evaluations and Supplier Risk Assessment on new sourcing in support of Global Council Steering Teams, identifying Risk Mitigation.
Drive closure of Supplier process Quality issues related to Stop Ship Builds, Field Service Actions, and BSAQ (Balanced Single Agenda for Quality) warranty projects.
Drive compliance to all organizational and corporate training requirements
Frequent Travel within NA, MX and/or Canada, depending on assigned supplier site locations
Established and active employee resource groups