Suspension PD Engineer

Ford • Dearborn, MI

8d • $65,100 - $166,200 • Hybrid

About The Position

Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life. We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more! In this position... Design and Release (D&R) Engineer position responsible for the end-to-end mechanical design, development, and production release of Leaf Spring systems for Ford vehicles. This role ensures that leaf spring components meet all functional, weight, cost, and quality requirements through the Global Product Development System (GPDS) cycle.

Requirements

• BS in Engineering Required
• Proven experience in Component Engineering or Design and Release, specifically within suspension systems or chassis components.
• Direct experience with Leaf Spring design, including knowledge of material properties, fatigue life, and rate linearity.
• Proficiency in creating and managing DFMEA, PFMEA, Control Plans, and 2D drawings with GD&T.
• Understanding of GPDS deliverables and milestones.
• Familiarity with CAE tools and the ability to interpret stress and fatigue analysis.
• Knowledge of supplier manufacturing processes for spring steel and/or composites.
• Strong analytical and math skills related to joint design and spring rate calculations.

Nice To Haves

• BS in Mechanical Engineering
• Position requires occasional travel to assembly plants and supplier manufacturing sites to support launch, process development, and issue resolution.
• Working knowledge of Ford engineering tools: Teamcenter, WERS, and the "buck" (digital packaging) environment.
• Travel may be significant during peak launch phases.
• On-site support for collaboration is required, targeting a minimum of 4 days per week.
• This position works closely with the Spring System Technical Expert to ensure global alignment on best practices and lessons learned.
• Self-starter with the ability to manage complex tasks under compressed program timing.
• Excellent communication skills with the ability to interface with Manufacturing, Purchasing, Suppliers, and Senior Leadership.

Responsibilities

• Lead the design, development, and release of leaf spring components and assemblies (including multi-leaf, mono-leaf, and composite applications).
• Own the engineering release process, including CAD data management in Teamcenter and releasing components via WERS.
• Manage multiple suppliers and support Supplier Technical Assistance engineers in delivering production parts with quality. This would entail on site visits with the suppliers to review their processes.
• Develop and maintain leaf spring engineering specifications, design rules, and foundation documents (RQTs).
• Lead technical design reviews with the Spring System Technical Expert and Component Supervisors.
• Responsible for component-level signoff and ensuring all DV/PV (Design/Performance Verification) testing is completed on schedule.
• Create and maintain leaf spring FMA (Failure Mode Analysis) documentation, including DFMEAs and SCCAFs.
• Lead root-cause analysis and problem-solving for leaf spring issues related to Launch, Quality/Field (TGW), and durability testing.
• Engage with Chassis Architecture, Chassis Systems Engineering, Vehicle Engineering (Vehicle Dynamics and NVH), Vehicle Evaluation and Verification, Vehicle Operations, and the Plant Vehicle Team to deliver robust suspension components and systems to final production that meet vehicle level performance requirements.
• Conduct manufacturing process reviews (forming, heat treatment, shot peening, and assembly) with suppliers to ensure design for manufacturability.
• Perform benchmarking studies to optimize leaf spring mass and cost for future vehicle programs.
• Manage interfaces with boundary components, including shackles, bushings, axle attachments, U-bolts, and frame interfaces.
• Utilize and maintain the leaf spring clearance calculator to ensure package integrity throughout the suspension travel.
• Leverage CAE modeling results to optimize leaf spring leaf thickness, taper, and stress distribution.
• Execute strategies for new technologies, specifically focusing on composite leaf springs.

Benefits

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