Senior Quality Engineer - Electrical & Electronics

Ford Motor; Chennai; Hybrid; INR 1,200,000 - 2,000,000; Full time

Job summary

Ford Motor in Chennai, India seeks a Senior STA Engineer Quality - Electrical & Electronics to lead warranty and field quality activities for automotive electronics and related systems. You will liaise with Ford plants, global suppliers, and engineering teams to identify and mitigate quality concerns, drive rapid containment actions, and establish robust corrective actions.

You will apply expertise in electronics hardware, failure analysis, and cross-functional problem solving to ensure

Qualifications

• Bachelor's degree in Electrical Engineering, Electronics Engineering, Mechatronics or related field.

Responsibilities

• Lead warranty and field quality investigations for automotive electronic components and systems.
• Coordinate cross-functional Global 8D investigations with plants, suppliers, engineering and quality teams.
• Facilitate structured root cause analysis using 8D, 5-Why, FMEA and other methods.
• Evaluate electronics failure data with X-ray, cross-sectioning, and diagnostic techniques.
• Monitor supplier quality across Tier 1–EMS and drive containment and corrective actions.

Skills

Automotive electronics

Quality management

Root cause analysis

8D

FMEA

APQP/PPAP

CAN

Automotive Ethernet

Education

Bachelor's degree in Electrical Engineering

Tools

CANoe/CANalyzer

Job description

STA Engineer Quality - Electrical & Electronics

The STA Engineer Quality - Electrical & Electronics - Electronics leads end-to-end warranty and field quality activities for automotive electronic commodities including body electronics, HVAC controls, infotainment and telematics systems, driver assistance technologies, powertrain and chassis controllers, sensors, actuators, and wiring interfaces. The role serves as the key liaison between Ford manufacturing plants, global suppliers, engineering teams, and quality organizations to identify, contain, investigate, and resolve product quality concerns. The successful candidate will leverage expertise in automotive electronics, supplier quality, manufacturing processes, warranty analysis, and structured problem-solving methodologies to ensure timely issue resolution and the prevention of recurring failures. This position requires strong technical leadership, cross-functional collaboration, and the ability to manage complex quality issues across multiple suppliers, manufacturing locations, and global regions.

Warranty & Field Quality Management

Lead warranty and field quality investigations for automotive electronic components and systems. Analyze warranty data, customer field reports, and manufacturing quality metrics to identify emerging concerns and prioritize corrective actions. Drive rapid execution of Interim Containment Actions (ICA) and ensure implementation of effective Permanent Corrective Actions (PCA).

Root Cause Analysis & Problem Solving

Lead cross-functional Global 8D (G8D) investigations involving manufacturing plants, suppliers, engineering teams, and quality organizations. Facilitate structured root cause analysis using methodologies such as 8D, 5-Why, Fishbone Diagram, Fault Tree Analysis (FTA), and Failure Mode and Effects Analysis (FMEA). Review and validate supplier failure analysis reports and challenge unsupported conclusions, including No Trouble Found (NTF) determinations.

Electronics Technical Assessment

Evaluate electronics failure analysis data, including X-ray inspection, cross-section analysis, decapsulation, thermal imaging, curve tracing, and related diagnostic techniques. Apply knowledge of automotive electronics hardware, PCB assemblies, connectors, sensors, actuators, power management devices, and embedded control modules to support issue resolution. Utilize vehicle diagnostic information, Diagnostic Trouble Codes (DTCs), and network communication data to identify affected modules and systems.

Supplier Quality Management

Monitor and improve supplier quality performance across Tier 1, Tier 2, and electronics manufacturing service (EMS) suppliers. Conduct supplier quality reviews, process assessments, and audits as required. Collaborate with suppliers to validate containment actions, corrective actions, and manufacturing process improvements. Support supplier compliance with quality management systems and automotive manufacturing standards.

Manufacturing Process & Compliance

Support implementation and compliance with Ford Electronics Manufacturing Requirements (FEMR), Ford Electronics Wiring Manufacturing Requirements (FEWMR), and applicable industry standards. Assess supplier manufacturing processes including Surface Mount Technology (SMT), Automated Optical Inspection (AOI), soldering processes, In-Circuit Testing (ICT), and End-of-Line (EOL) testing. Verify effectiveness of process controls, testing strategies, and quality systems used to prevent defects.

Reliability & Validation

Support Review supplier validation and reliability test results, including thermal cycling, thermal shock, vibration, humidity, electromagnetic compatibility (EMC), and environmental testing. Assess component and product qualification evidence to support robust corrective actions and long-term reliability improvements.

Cross-Functional & Global Collaboration

Coordinate warranty part return activities and support failure analysis logistics to ensure timely investigation. Partner with engineering, manufacturing, software, systems, and supplier teams to resolve hardware, software, and system integration issues. Prepare technical summaries and quality status reports for leadership reviews. Escalate critical quality concerns with clear recommendations and risk assessments when safety, customer satisfaction, or warranty exposure is impacted. Communicate effectively with global teams across multiple cultures, regions, and time zones.

Required Qualifications

• Bachelor's degree in Electrical Engineering, Electronics Engineering, Mechatronics Engineering, Systems Engineering, or a related technical field.
• Minimum of 6 years of experience in automotive electronics, supplier quality, manufacturing quality, product engineering, or a related discipline.
• Experience supporting warranty investigations, field quality resolution, and root cause analysis.
• Strong knowledge of electronics hardware fundamentals, including PCB assemblies, integrated circuits, sensors, actuators, connectors, and power electronics.
• Experience using structured problem-solving methodologies such as 8D, 5-Why, FMEA, and Fault Tree Analysis.
• Understanding of automotive quality systems and tools, including APQP, PPAP, SPC, and MSA.
• Working knowledge of automotive communication protocols and diagnostics, including CAN, LIN, Automotive Ethernet, and Diagnostic Trouble Codes (DTCs).
• Strong communication, collaboration, negotiation, and stakeholder management skills.
• Ability to travel domestically and internationally as required.

Preferred Qualifications

• Experience working within automotive OEM, Tier 1, Tier 2, or Electronics Manufacturing Services (EMS) environments.
• Certified Quality Engineer (CQE), Six Sigma Green Belt, Six Sigma Black Belt, or VDA 6.3 Process Auditor certification.
• Knowledge of ISO 26262 Functional Safety, IATF 16949, IPC-A-610, AEC-Q100/Q200, EMC/EMI standards, and automotive electronics reliability requirements.
• Experience with automotive diagnostic tools such as Vector CANoe, CANalyzer, or equivalent platforms.
• Familiarity with electronics failure analysis techniques including X-ray inspection, decapsulation, cross-sectioning, thermal imaging, and related methodologies.
• Experience auditing global automotive electronics suppliers and managing supplier corrective action processes.
• Knowledge of Ford Electronics Manufacturing Requirements (FEMR) and Ford Electronics Wiring Manufacturing Requirements (FEWMR).
• Multi-language proficiency is considered an advantage when supporting global supplier and manufacturing networks.

Experience Level

Senior Level