STA Engineer Quality Electrical And Electronics

Ford Motor Company; Chennai District; On-site; INR 1,800,000 - 3,600,000; Full time

Job summary

Ford Motor Company is seeking a STA Engineer Quality – Electrical & Electronics to lead warranty and field quality activities across automotive electronics including body electronics, infotainment, and sensor systems. This role interfaces with Ford plants, suppliers, and engineering teams to identify, contain, and resolve quality issues with robust corrective actions.

The ideal candidate has 6+ years in automotive electronics quality, strong problem-solving skills, and experience with 8D, FMEA,

Qualifications

• Bachelor's degree in Electrical Engineering, Electronics Engineering, Mechatronics, Systems Engineering, or related field.
• Minimum 6 years in automotive electronics or related quality disciplines.
• Experience with warranty investigations, field quality resolution, and root cause analysis.
• Strong knowledge of electronics hardware fundamentals: PCBs, sensors, actuators, connectors, and power electronics.
• Experience with 8D, 5-Why, FMEA, and Fault Tree Analysis.
• Knowledge of APQP, PPAP, SPC, MSA, and automotive quality systems.
• Understanding CAN, LIN, Automotive Ethernet, and DTCs.
• Excellent communication and cross-functional collaboration; able to travel domestically and internationally.

Responsibilities

• Lead warranty and field quality investigations for automotive electronic components and systems.
• Analyze warranty data and field reports to identify concerns and prioritize actions.
• Drive Interim Containment Actions and permanent corrective actions.
• Lead Global 8D investigations with suppliers, plants, and engineering teams.
• Perform structured root cause analysis using 8D/5-Whys/FTA/FMEA.
• Review and validate supplier failure analyses and NTF determinations.
• Evaluate electronics failure data using X-ray, decap, thermal imaging, and curve tracing.
• Coordinate with cross-functional teams to resolve hardware, software, and system integration issues.
• Prepare technical summaries and risk assessments for leadership.
• Ensure compliance with FEMR/FEWMR and testing standards.

Skills

Automotive electronics

Supplier quality

Quality engineering

8D problem solving

FMEA

APQP/PPAP

DTCs diagnostics

CAN/LIN/ECU basics

Communication

Education

Bachelor's in Electrical/Electronics/Mechatronics/Systems

Tools

Vector CANoe

X-ray analysis

Cross-sectioning

FTA/FMEA software

Job description

Job Description:

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.

Responsibilities

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.

Qualifications

Required Qualifications

• Bachelors 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.

Requirements: