STA Engineer Quality - Electrical & Electronics

Ford; Chennai District; On-site; INR 1,200,000 - 2,400,000; Full time

Job summary

Ford India seeks a STA Engineer in Quality for Electronics to lead warranty and field quality activities across automotive electronic systems. You will collaborate with manufacturing plants, suppliers, and engineering teams to identify, contain, investigate, and resolve quality issues using 8D, 5-Why and FMEA methods to prevent recurrence.

The role requires strong technical leadership, cross-functional teamwork, and travel as needed to ensure reliable electronic modules and compliance with

Qualifications

• Bachelor's degree in Electrical or Electronics or Mechatronics, or Systems Eng.
• Minimum 6 years in automotive electronics or quality disciplines.
• Experience with warranty investigations, field quality, and root cause analysis.
• Knowledge of PCB assemblies, sensors, actuators, and power electronics.
• Familiarity with 8D, 5-Why, FMEA, and Fault Tree Analysis.

Responsibilities

• Lead warranty and field quality investigations for automotive electronics.
• Analyze warranty data and field reports to prioritize corrective actions.
• Drive containment actions and implement permanent corrective actions.
• Lead cross-functional G8D investigations with plants, suppliers, and engineering.
• Evaluate electronics failure data and support issue resolution.
• Collaborate with suppliers to validate containment and corrective actions.
• Support FEMR and FEWMR compliance and process controls.
• Coordinate with global teams and provide leadership updates.

Skills

Warranty investigations

Root cause analysis

8D problem solving

Automotive electronics

Supplier quality

Cross-functional leadership

DTC analysis

Communication skills

Education

Bachelor's degree in Electrical/Electronics/Mechatronics/Systems Engineering

Tools

Vector CANoe

CANalyzer

IPC-A-610

Job description

The STA Engineer QualityElectrical & 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.