As an Assembly Testing Engineer at Ford, you will be a critical expert within the Powertrain Manufacturing Engineering (PTME) team, primarily focused on the development, implementation, and optimization of assembly methods, equipment, and comprehensive testing strategies for a wide range of powertrain components. Your role will span from traditional Engine, Transmission, and Axle assemblies to advanced Power Unit, Rotor/Stator, and Battery Array/Module/Pack assemblies for electrified vehicles. You will be responsible for defining Bill of Process standards for all assembly and testing sequences, ensuring robust, high-quality, and ergonomically sound manufacturing solutions. This position requires a strong blend of process engineering, quality assurance, virtual manufacturing expertise, and a keen focus on developing and deploying effective test methods for various sub-assemblies. You will collaborate extensively with product engineering, manufacturing plants, and suppliers to drive continuous improvement and achieve world-class assembly and testing performance.
Your role will encompass program leadership, technical process development, and financial stewardship. Key responsibilities include:
Assembly Process & Standards Development:
Develop and maintain Bill of Process (BoP) standards for all assembly methods and equipment specifications (sequence, clamping, fastening, pressing, testing, etc.).
Develop assembly process sequences in Global Study Process Allocation System (GSPAS).
Develop process book/functional specification for each station and identify key tooling components for Bill of Material (BoM), and develop 3D models.
Deploy standard engineering methods in the development and delivery of assembly processes and systems.
Benchmark existing assembly systems, including Engine Assembly, Transmission Assembly, Axle Assembly, Power Unit Assembly, Rotor and Stator Manufacturing, and Battery Array, Module & Pack Assembly.
Testing Methodologies & Implementation:
Responsible for all sub-assemblies and test methods, including Cylinder Head Assembly, Piston and Rod Assembly, Planetary Carrier Assembly, off-line assemblies, Main Control Assemblies, etc.
Develop and maintain robust processes, and mitigate/eliminate all identified failure modes and risks for new programs through Failure Mode Avoidance (e.g., PFMEA, Control Plans, SCCAF, EPM).
Workstation & Equipment Design:
Develop standard layouts for the overall assembly system and manual workstations.
Deliver manual workstations based on standardized work, including line-side material handling equipment and tooling (tool/bridge rail systems, lift assists, flow racks and fork-free unit load lifts/carts), line-side part placement, and assessment of safety and ergonomic risk factors.
Determine appropriate material handling requirements (i.e., tool rail systems, lift assists, material racks, etc.).
Utilize Virtual Manufacturing for simulation verification and workstation development.
Support the development of 3D station models to easily share with the supply base.
Feasibility & Cost Management:
Provide manufacturing assessments, cost estimates, and feasibility input for future model cost studies.
Support new model program cost studies and projects.
Quality & Continuous Improvement:
Support the Design for Ergonomics procedure for assembly processes to drive Zero Ergonomic issues through engineering.
Support continuous improvement of Assembly Systems and the introduction of new technologies.
Assist plants, as required, in resolving significant engineering issues and achieving continuous improvement for both new programs and current production.
Cross-Functional Collaboration:
Support the Quality Operating Systems and Ford Production System (FPS).
Support simultaneous engineering and feasibility engineering studies among product engineering and production facilities.
Provide technical expertise to Powertrain Operations (PTO) plants & support strategic priorities.
Education: Bachelor’s degree in Engineering (Mechanical, Electrical, Manufacturing, or related).
Experience: Professional experience in manufacturing engineering, with a strong focus on assembly processes, equipment, and testing methodologies. Experience with new product introduction (NPI) and the Global Product Development System (GPDS) and familiarity with powertrain assembly (ICE, Transmission, Axle) and/or electrification components (Power Unit, Battery Assembly) is highly preferred.
Technical Knowledge:
Proficiency in developing Bill of Process (BoP) standards for assembly and testing.
Strong understanding of assembly methods (clamping, fastening, pressing), material handling, and workstation design.
Experience with Virtual Manufacturing tools for simulation and workstation development.
Knowledge of Failure Mode Avoidance tools (PFMEA, Control Plans) and ergonomic analysis for assembly processes.
Familiarity with Global Study Process Allocation System (GSPAS) is a plus.
Language Skills: Advanced proficiency in English (written and verbal) for global reporting and cross-functional collaboration.
Soft skills:
Excellent analytical and problem-solving skills to optimize assembly processes and resolve testing issues.
Strong communication and collaboration skills to work effectively with product engineering, plant teams, and suppliers.
Detail-oriented with a focus on quality, ergonomics, and continuous improvement.
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