Job Description

The Supplier Quality Resident Engineer(Plant Resident STA) will be stationed at Ford manufacturing plant and serves as the key technical and quality interface between Ford plant and supply base. This role is responsible for resolving any part quality(external suppliers) issue reported at Ford plant & in warranty. The Resident Engineer ensures that the issue is communicated to eternal suppliers, SITE STA Engineers & product development teams.

In addition, the Resident STA may also travel to the external suppliers on need basis to follow APQP/PPAP.

• Lead critical supplier process to drive supplier Quality Reject (QR) performance.
• Support QR (Quality Reject) procedures, by supporting concern binning, reviewing threshold QR’s, and providing support for dispute resolution. Assist IQ (Incoming Quality) with non-responsive suppliers. Assist suppliers and plants in QR/PPM (Parts Per Million) data accuracy. Administer part quality confirmation process for suppliers with repetitive containment failure.
• Participate in Whiteboard, Variable reduction team(VRT) meetings etc. as needed on an exceptional basis. Drive resolution of external supplier process 3MIS warranty concerns through supplier notification and driving containment at the supplier.
• Lead containment of special cause supplier process 3MIS warranty projects.
• Align with VRT (Variability Reduction Team) on SP (Supplier Process) BSAQ Glidepath values.
• Provide early notification to and engage STA Site team on potential stop shipments which are related to supplier process. Provide support in containing supplier stop ship issue. Work with Stop Ship Stakeholders to support proper root cause owner is identified for PAC (Prevent Action Closure).
• Monitor daily production report and provide notification to STA management for issues that require STA awareness/intervention.
• Coordination between STA and plant management, lead supplier preparation for Global Quality reviews.
• Lead structured problem-solving efforts utilizing 8D, 5-Why analysis, fault-tree analysis, and data-driven root-cause validation.
• Participate in quality review meetings and support resolution of supplier-driven warranty and field-quality concerns.
• Awareness on Advanced Product Quality Planning (APQP), Production Part Approval Process (PPAP), launch, ramp-up, and current production.
• Bachelor's degree in Mechanical Engineering, Automotive Engineering, Manufacturing Engineering, Industrial Engineering, or a related discipline.
• Minimum of 6 years of experience in Supplier Quality, Supplier Technical Assistance (STA), Manufacturing Engineering, Product Quality, or Powertrain Engineering within the automotive industry.
• Experience supporting suppliers serving major automotive OEMs.
• Working knowledge of:
• APQP
• PPAP
• PFMEA
• Control Plans
• Process Flow Diagrams
• Statistical Process Control (SPC)
• Measurement System Analysis (MSA)
• Gage R&R
• GD&T
• IATF 16949 requirements
• Experience in transmission, driveline, axle, or powertrain component manufacturing processes including casting, forging, heat treatment, gear machining, welding, and assembly.
• Strong analytical and problem-solving skills utilizing 8D, 5-Why, and Root Cause Analysis methodologies.
• Advanced Microsoft Excel and PowerPoint skills, including data analysis, dashboards, issue tracking, and executive-level presentations.
• Ability to travel and work directly with supplier manufacturing locations.

Preferred

• Experience with engine or transmission systems and components.
• Knowledge of CQI special-process requirements.
• Lean Manufacturing and Six Sigma certification or practical application experience.
• Experience supporting transmission or engine supply chains for global automotive manufacturers.