Manufacturing Engineer

Optimal Solution Company; Sterling Heights (MI); On-site; USD 95,000 - 125,000; Full time

Job summary

Ford Motor Company in Sterling Heights, MI is seeking a Gear Machining Launch Process Engineer to collaborate with the headquarters launch team and suppliers, ensuring the gear machining line meets key metrics for long-term success.

The role supports process engineering for gear machining, drives safety and quality improvements, completes PPAP documentation, and applies engineering principles to continuously improve manufacturing processes and products.

Qualifications

• 5+ years of related experience.
• Leadership and interpersonal skills.
• 8D and 5Why corrective action skills.
• Hypoid Bevel gear process understanding (blanking, milling, hobbing, grinding, heat treat, shot peening, hard turn, lapping).
• Quality Assessment tools (QDAS, Minitab).

Responsibilities

• Support Manufacturing Process Engineering activity for Gear machining.
• Drive continuous improvement in safety, quality and productivity.
• Complete all PPAP quality launch documentation.
• Apply engineering principles and analytical techniques to establish and continuously improve manufacturing processes and products.
• Develop action plans to investigate and prioritize open issues and verify corrective actions on internal and supplier processes.
• Lead and conduct process audits to ensure process discipline.
• Conduct job ergonomic evaluations and deliver corrective actions as required.
• Create process and instruction sheets supporting quality methods and processes.
• Deliver capable processes and tools for all gear machining operations.
• Lead variability reduction and lean manufacturing initiatives and best practices.
• Ensure compliance to Plant, Corporate, Governmental and Environmental standards.
• Support ISO 14001 compliance and internal auditing.
• Identify throughput constraints and drive root cause improvements to achieve Rate of Climb targets.

Skills

Statistical Process Controls

Machining

Lean Manufacturing

PPAP

Gear machining

Education

High School Diploma / GED

Bachelor's Degree

Job description

Position Description:

This role is for gear machining launch process engineer. You will work jointly with the headquarters launch team and their suppliers to assure the incoming manufacturing line is successfully delivered for all key business metrics for long-term success of Ford Motor Company.

Job Responsibilities:

• Support Manufacturing Process Engineering activity for Gear machining
• Drive continuous improvement in safety, quality and productivity
• Complete all PPAP quality launch documentation
• Apply engineering principles and analytical techniques to establish and continuously improve manufacturing processes and products
• Develop action plans as required to investigate and prioritize open issues and verify corrective actions on internal processes and supplier processes
• Lead and conduct process audits to ensure process discipline is consistent with Powertrain guidelines
• Conduct job ergonomic evaluations and deliver corrective actions as required
• Create process and instruction sheets supporting quality methods and processes
• Deliver capable processes and tools for all gear machining operations
• Lead variability reduction and lean manufacturing initiatives and best practices
• Ensure compliance to Plant, Corporate, Governmental and Environmental standards
• Support ISO 14001 compliance and support internal ISO auditing and compliance as required
• Identify throughput constraints and drive root cause improvements to achieve Rate of Climb targets.

Skills Required:

Statistical Process Controls, Machining, Lean Manufacturing, PPAP, Gear machining

Skills Preferred:

Lean Six Sigma, Machinery, Root Cause Analysis

Experience Required:

• Experience: 5+ yrs of related experience
• Successful candidate must be able to demonstrate leadership behaviors combined with outstanding interpersonal, teambuilding, and communication skills
• 8D and 5Why corrective action and problem solving skills
• Hypoid Bevel gear process understanding (blanking, milling, hobbing, grinding, heat treat, shot peening, hard turn, lapping)
• Quality Assessment tools (QDAS, Minitab)

Experience Highly Preferred:

• Klingelnburg P40 & Gleason Nano Gear CMM
• Effective oral and written communication skills
• Lean Manufacturing and Six Sigma experience
• Lean Tools - 5S, Kanban, Poka-yoke, and Value Stream Mapping
• DMAIC and DMADV (DFSS) Project Methodology experience
• FMEA, PPAP, and DOEs experience

Education Required:

High School Diploma / GED

Education Preferred:

Bachelor's Degree

Additional Information:

Fully Onsite.

Use of AI Technology:

Unless expressly authorized in the interview/skill set validation instructions, candidates may not use AI tools or other third-party assistance during an interview or assessment to generate or provide substantive answers to interview questions. Candidates should answer organically in their own words, drawing on their own knowledge, skills, and experience. Failure to adhere to these expectations may result in the candidate being removed from consideration.