Engineering Specialist: Process - Ford Motor Company

ROLE SUMMARY

The Engineering Specialist – Process: Leads Manufacturing Process Engineering for Final Assembly (Trim/Chassis), driving continuous improvement in safety, quality, and productivity. This role is central to program launch management and readiness, overseeing all aspects from initial planning to production. 

Responsibilities

PERFORMANCE MEASURES/ SUCCESS CRITERIA:

• Implement Zero Defect / Error-Proofed Processes.
• No downtime related to jig/fixtures within Chassis and/or trim areas.
• Deliver a zone FRC greater than 97%.
• Ensure process audits are conducted within specified timing as per company policy.
• Complete a minimum of two Green Belt projects per year.
• Ensure within a two-year period from enrolment, that candidate is Green Belt certified.
• Layouts, material flow diagrams, and pedestrian flow meet standards.
• Risk assessments are completed for design, build, modification, and commissioning of equipment.
• Pre-Task Assessment signed off for skilled trades/contractor work.
• PROTAG sign-off supported to plan, and punch list items followed to completion.
• JSA completed for processes prior to TT build.
• Robust 8D/5D/4D closure actions for build issues.
• Plant QOS processes active and complete (Gauging strategy, equipment capability, traceability/QLS; DCP, OIS/WES, QCM, Error Proofing systems operational, Inspection Processes).
• High Hurts Matrix reviewed and updated.
• Achieve, verify, and maintain all production quality requirements during build phase.
• Whiteboard, AIMs and build issue manufacturing ensure all issues have ICA/PCA.
• Build Quality Metrics for each build milestone.
• Teardown results and test result corrective actions incorporated.
• Program delivered within current model constraints, with content analysis complete.
• Zoning completed prior to GDPS milestones with no new launch-related open issues.
• Workstation Readiness Assessment (WSR) completed with zero open issues prior to GDPS milestones.
• Part sign-off prior to build phase for all Non-PPAP parts completed.
• Cost-saving projects implementation.
• Kaizen projects implementation.
• BBQ and all backup tooling is available.
• Equipment power consumption minimized.

POSITION DETAILS - Manufacturing Process Engineering & Continuous Improvement:

• Lead Manufacturing Process Engineering activities for Final Assembly, with a focus on Trim and Chassis Assembly operations.
• Drive continuous improvement in safety, quality, and productivity across all manufacturing processes.
• Apply engineering principles and analytical techniques to establish and continuously improve manufacturing processes and products.
• Develop action plans to investigate and prioritize quality concerns and verify corrective actions on internal processes and supplier processes.
• Conduct process audits to ensure process discipline consistent with Vehicle Operations guidelines, adherence to process outline, and drive continuous improvement.
• Conduct job ergonomic evaluations and deliver corrective actions as required.
• Analyse vehicle inventory root causes; engage in mapping and corrective actions to reduce vehicle inventory.
• Deliver capable processes and tools for Trim and Chassis Assembly operations.
• Lead in resolving assembly-related concerns. Lead variability reduction and lean manufacturing initiatives and best practices.
• Identify throughput constraints and drive root cause improvements.
• Identify and drive to closure all FRC issues within Chassis and/or Trim areas.
• Maintain fixture/jig integrity within your responsible zone along with required backups.
• Identify and close all control plan items marked as red within your respective zones.
• Support MTC changes and efficiency activities within Chassis and/or Trim areas.
• Support warranty investigations in Chassis and/or Trim areas.

Program Launch Management & Readiness:

• Confirm layouts, material flow diagrams, and pedestrian flow meet standards for new programs.
• Ensure new parts are plotted and will fit on the station, and layout demarcations meet layout standards (CLL).
• Support all aspects of build events (Slow Build, TT, PP, MP1, FCPA, FER), including participating and leading "war room" meetings, capturing and binning build issues, ensuring robust 8D (Quality Operating System)/5D          (Launch Quality Operating System 800)/4D (Manufacturing Operating System) closure actions, and sending out quality scorecards and night letters.
• Review changes in product and process that may impact the plant manufacturing process or operational plan, delivering programs within current model constraints (operational costs including lost units, scrap, industrial material, labour).
• Conduct content change analysis with the launch team to understand the impact on processes and facilities,ensuring appropriate countermeasures and training are implemented.
• Ensure Zoning is completed prior to all GDPS (Global Development Process System) milestones (TT, PP, MP1) with no new launch-related open issues and ensure carry-over items are moved to DCC or MCC for the department.
• Lead the Workstation Readiness Assessment (WSR) as per standard, ensuring zero open issues, and that the WSR is followed using the appropriate check sheet three weeks before every build phase.
• Ensure Part sign-off prior to build phase for all Non-PPAP (Production Part Approval Process) parts and ensure part delivery to team members doesn’t cause any damages or issues, coordinating with MP&L (Material Planning & Logistics) to isolate launch parts.

Quality Operating Systems (QOS) & Compliance:

• Ensure that Plant QOS processes are active and complete, covering gauging strategy, equipment capability,traceability (QLSCM), DCP (Data Collection Point), OIS (Operator Instruction Sheet)/WES (Work Element Sheet),QCM (Quality Control Method), error-proofing systems, and inspection processes.
• Ensure correct measurement system/gauge selection, Gauge R&R study completion, functional QLS systems with appropriate definitions, CDC configuration to confirm traceability, part traceability on EP (Error Proofing),and calibration of DC tools and bench calibration.
• Ensure QCM updates are in line with new content and able to assist build, ensure all items from the control plan are implemented and validated during build, ensure OIS/WES is up to date and released on Launch APT plan, ensure EQI layout is in line with content change, and adapt QCM's based upon missed inspection and perform quality recalibration.
• Review and understand the High Hurts Matrix, ensuring previous High Hurts are implemented to upcoming programs and validated, and populate/hand over the HH list with CFT (Cross-Functional Team) into a consolidated list to PVT-ME / VME.
• Support Whiteboard meetings to ensure all issues have ICA (Interim Containment Action)/PCA (Permanent Corrective Action) within 24 hours, and support achieving, verifying, and maintaining all production quality requirements during build phases.
• Ensure that teardown results and test result corrective actions are incorporated into the manufacturing and EOL (End of Line) testing process.

Safety, Health & Environmental Compliance:

• Ensure that Risk Assessments are completed for the Design, Build, Modification, and Commissioning of Equipment (Concept, Design, Build and Runoff, Launch phase, Modifications to existing equipment).
• Ensure that Pre Task Assessment is signed off for skilled trades/contractor work (review at specified intervals).
• Support PROTAG sign-off to plan, guiding plant personnel (Plant Operations and Skilled Trades) through White-to-Pink, Pink-to-Yellow, and Yellow-to-Green phases, and reviewing PROTAG status and punch list completion.
• Ensure the work area has appropriate signage posted and clearly visible in case of exposure to hazards,including approved Toxicology (TOX) numbers, identifying new chemicals and ensuring proper loading /labelling as per procedure (FAS08-252 Chemical Hazard Communication Standard).
• Ensure Job Safety Analysis (JSA) is completed for processes prior to TT build.
• Ensure that BBQ (Bypass, Backup, or Quick response) and all backup tooling is available per the BBQ strategy(MOS BBQ Assessment form).
• Ensure compliance to Plant, Corporate, Governmental, and Environmental standards.
• Support ISO 14001 compliance and support internal ISO auditing and compliance as required.
• Ensure safe and proper disposal of equipment as applicable.
• Ensure equipment power consumption is minimized when equipment and facilities are not being used (auto shutdown mode/turn off when not being utilized).
• Ensure that handling, cleaning, and corrosion protection of metal parts are followed.

Cost Initiatives:

• Lead one cost-saving project to implementation per year
• Implement one Kaizen project per month.
• Communication and working relationships: This role requires extensive collaboration and communication with Manufacturing Leadership, Quality, Production, Maintenance, LPWR, Product Development, Vehicle Manufacturing Engineering (VME), external suppliers, and cross-functional teams to ensure seamless operations and successful program launches.

KNOWLEDGE, SKILLS and ABILITIES (KSA):

Technical Skills:

• Lean Manufacturing and Six Sigma experience.
• 8D and 5Why corrective action and problem-solving skills.
• Lean Tools – 5S, Kanban, Poka-yoke, and Value Stream Mapping.
• DMAIC and DMADV (Design for Six Sigma) Project Methodology experience.
• TQM (Total Quality Management) and Kaizen Methods.
• FMEA (Failure Mode and Effects Analysis), PPAP, and DOEs (Design of Experiments) experience.
• Ergonomic analysis knowledge and experience.
• GSPAS/APT.
• CLL/Auto CAD.
• Wow Falcon / WERS.
• Illustration, MOVIS, AIS.
• Knowledge of Plant Layout, Material Flow Diagram, Pedestrian Flow standards (e.g., FAS08-079).
• Risk Assessment methodologies (e.g., FAS08-036).
• PROTAG procedures and sign-off processes.
• Chemical Hazard Communication Standard (FAS08-252) and Toxicology (TOX) number management.
• Job Safety Analysis (JSA).
• Quality Operating System (QOS) processes, including Gauging (e.g., PTS02-081ME, PTP07-015), Traceability (e.g., FAP02-007, PTS02-112ME), QLS, CDC, Calibration (e.g., FAP03-015, PTP07-111, PTP07-120),
• High Hurts procedures (e.g., PTP02-183ME, LQOS 802).
• Experience with Production FIS/IIOT systems.
• Build event management (TT, PP, MP1, FCPA, FER) and related procedures (e.g., PTP02-113ME MLP, PTP03-115 PTR, LQOS 800/815/530/824).
• Workstation Readiness Assessment (WSR).
• LPWR processes and eFPS.

Competencies:

• Effective oral and written communication skills.
• Strong leadership capabilities (ONE FORD behaviors).
• Outstanding interpersonal, teambuilding, and communication skills.
•  Ability to deeply understand user intent and provide clear, accurate answers.
• Problem-solving and analytical thinking (8D, 5Why).
• Ability to drive continuous improvement and lean manufacturing initiatives.
• Strong organizational and planning skills.
• Results-oriented with a focus on meeting KPIs.
• Collaboration across diverse teams.
• Proactive in identifying and addressing challenges.
• General attributes: (As implied by the above)
•  Linguistic skills: Effective oral and written communication skills

QUALIFICATIONS and EXPERIENCE   

Preferred Requirements:

• Education: Bachelor’s degree in Mechanical / Electrical or Industrial engineering. 
• Experience: 5+ yrs of related experience.
• A certified green belt has an advantage.
• Ariba access and use has advantage.
• Successful candidate must be able to demonstrate leadership in ONE FORD (leadership) behaviors combined with outstanding interpersonal, teambuilding, and communication skills.