Structural Systems, Core Engineer

Ford • Dearborn, MI

6d

About The Position

Core engineering is responsible for all Structures core documents as well as assisting component design engineers with the design, testing, sign off, and launch of cost-effective high quality structural systems and components Institutionalize knowledge and best practices by authoring core documents including engineering requirements, design rules, engineering specifications, test methods, and failure mode avoidance documents such as quality history, interface diagrams, boundary diagrams, DFMEA, critical and significant characteristics. Develop, author, and implement standards based on permanent corrective actions and training to correct systemic failures and escape points. Develop the comprehensive Specification Document for anti-vibration solutions, defining parameters such as stiffnesses (Kd/Ks), damping (Tan delta or Loss Angle), and splines (force vs deflection). Develop representative block cycles using Road Load Vehicle data tailored for the specific component interfaces the engineer is responsible for. Effectively communicate the inherent tradeoffs between Vehicle Engineering requirements and the limitations of the mount design, which are often constrained by packaging, durability, or hardware restrictions. Ensure component engineers are designing, testing, and signing off components with quality by conducting design reviews and reviewing and approving DVP&R evidence as part of the engineering sign off process. Conduct design reviews with engineers to optimize component and system designs. Joining feasibility assessments of new, program specific material combinations. Lead planning, execution, and evaluation of new materials, new coatings, and new joining methods via internal and external laboratories in conjunction with Materials Engineering, Corrosion Engineering, R&A, suppliers, and other Structures Technical Specialists and SMEs which deliver future strategic Structural Systems solutions. Play both support and lead roles solving production issues with component engineers, supplier technical assistance, materials engineering, purchasing, and vehicle operations engineers. Examples include stop ship/stop build, field service actions, warranty, and material shortages. Support cross functional teams to identify, develop and deliver new / strategic design solutions which deliver BIC Quality, Cost and Weight objectives. Benchmark competition and develop advanced projects to ensure Ford is BIC Close cooperation with CAE team for the development of simulation methods, material cards, and joining method cards.

Requirements

• B.S. in Mechanical Engineering or a related physical science field of study.
• 5+ years as an automotive structural design engineer or similar experience.
• MUST HAVE experience with antivibration solutions such as Body Mounts, Engine Mount, or Dampers. (Highly relevant to automotive performance, comfort, and structural integrity).
• Working knowledge or experience on reproducing block cycle testing for rubber-to-metal components. (Important for validating material and component durability under realistic conditions).
• Experience in all program phases from Pre-Program through Launch, including one major program.
• Experience creating failure mode avoidance documents, specifically DFMEAs, and identifying significant and critical characteristics.
• Demonstrated ability to provide improvements in customer satisfaction, reduction in warranty, or total cost reduction.
• Working knowledge or experience in joining methods such as spot welding, clinching, and riveting. (Crucial for understanding how automotive structures are assembled and their integrity).
• Working knowledge or experience in fastener design and testing. (Essential for structural connections and overall vehicle safety/durability).
• Working knowledge or experience in materials engineering or corrosion engineering. (Fundamental for selecting appropriate materials and ensuring long-term structural durability).
• Working knowledge or experience using CAE and CATIA. (These are industry-standard tools for design, analysis, and simulation in automotive structural engineering).
• Working knowledge or experience using N-Code and creating block cycles. (Specific tools and techniques for advanced durability and fatigue analysis, directly supporting structural design).
• Working knowledge or experience on elastomer material testing. (Directly related to understanding and selecting materials for components often used in structural and anti-vibration applications).

Nice To Haves

• Multiple automotive launches. (Demonstrates broader program experience and a deeper understanding of the entire product lifecycle beyond a single major program).
• M.S. in Mechanical Engineering, Industrial Engineering, or a related physical science field of study. (An advanced degree provides a stronger theoretical foundation and problem-solving capabilities).
• (A versatile tool for data analysis, modeling, and algorithm development, often used in conjunction with other engineering software).
• Demonstrated capability to teach, coach, and mentor technical knowledge.
• Self-starter - ability to work effectively with little oversight

Responsibilities

• Authoring core documents including engineering requirements, design rules, engineering specifications, test methods, and failure mode avoidance documents
• Develop, author, and implement standards based on permanent corrective actions and training
• Develop the comprehensive Specification Document for anti-vibration solutions
• Develop representative block cycles using Road Load Vehicle data
• Effectively communicate the inherent tradeoffs between Vehicle Engineering requirements and the limitations of the mount design
• Ensure component engineers are designing, testing, and signing off components with quality
• Conduct design reviews with engineers to optimize component and system designs
• Joining feasibility assessments of new, program specific material combinations
• Lead planning, execution, and evaluation of new materials, new coatings, and new joining methods
• Play both support and lead roles solving production issues
• Support cross functional teams to identify, develop and deliver new / strategic design solutions
• Benchmark competition and develop advanced projects
• Close cooperation with CAE team for the development of simulation methods, material cards, and joining method cards

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