Process Engineer, Ford Energy

Alfa Laval Inc.; Glendale Junction (KY); On-site; USD 65,100 - 144,900; Full time

Benefits offered by this job

Medical coverage

Dental coverage

Vision coverage

Vehicle discount program

Tuition assistance

Paid holidays

Paid time off

Job summary

Ford Energy in Glendale Junction is seeking a Process Engineer to launch and scale operations at a high-volume battery storage plant. You will drive the FEPS, standardize work, optimize line layouts, and build labor standards across cell, module, and pack assembly.

Ideal candidates have 3–5+ years in Industrial/Manufacturing Engineering, a Bachelor’s in Engineering, and experience with lean tools and CAD. This role requires US work authorization and willingness to travel domestically.

Qualifications

• Bachelor’s degree in Engineering (Mechanical, Electrical, Chemical, Industrial, Manufacturing or related).
• 3–5+ years in Industrial/Manufacturing Engineering in high-volume production.
• Experience with Greenfield site development or automotive/battery/electronics manufacturing is a plus.
• Familiarity with lean tools (5S, Kanban, Poka-Yoke, Value Stream Mapping) is desirable.

Responsibilities

• Lead design and implementation of the Ford Energy Production System (FEPS) focusing on standardized work, line balancing, and efficient workstation layouts.
• Develop labor standards and manpower plans for cell, module, and pack assembly.
• Drive safety, quality, and productivity across all production lines.
• Perform cycle time studies to optimize throughput, JPH, and First Time Through (FTT).
• Collaborate with Product Design, suppliers, and manufacturing to develop optimal process strategies.

Skills

Line balancing

Lean manufacturing

Six Sigma

Capacity modeling

Data-driven decisions

Education

Bachelor's degree in Engineering

Tools

AutoCAD

MODAPTS

Manufacturing simulation tools

Job description

Ford Energy is a newly formed, wholly-owned subsidiary of Ford Motor Company dedicated to accelerating U.S. energy independence. Leveraging Ford’s century of manufacturing excellence and world-class battery energy storage systems (BESS) technology, Ford Energy designs, manufactures, and services grid-scale and commercial DC battery energy storage systems (BESS). Ford Energy is uniquely positioned to capture the growing demand for reliable, US-built energy storage systems. We are not just building batteries; we are building the infrastructure for the next generation of the American grid.

Why Ford Energy?

At Ford Energy, you have the backing of an industrial manufacturing powerhouse with the agility of a dedicated energy startup offering industry leading technology. We offer a competitive compensation package including performance-based bonuses, Ford vehicle discounts, and the opportunity to shape the energy strategy of one of the world's most iconic brands.

In this position...

As a Process Engineer, you will play a critical role in launching and scaling operations at our Glendale Junction facility. This is a high-impact, startup role within a legacy manufacturing powerhouse.

You will:

• Lead with Purpose: Apply engineering principles and analytical techniques to establish, optimize, and continuously improve high-volume battery storage manufacturing and assembly processes.
• Innovate: Use your entrepreneurial mindset to drive production throughput, line balancing, and labor efficiency for a massive Greenfield manufacturing site.
• Empower Others: Create a culture of lean manufacturing excellence, fostering an environment where standardized work and data-driven production solutions thrive

What you'll do...

• Greenfield Production Excellence & Manufacturing SystemsLead the design and implementation of the Ford Energy Production System (FEPS), with a focus on standardized work, line balancing, and optimized workstation layouts.
• Develop labor standards and manpower plans for cell, module, and pack assembly to maximize utilization and efficiency.
• Drive continuous improvement in safety, quality, and productivity across all production lines.
• Analyze production constraints and perform equipment cycle time studies to optimize throughput, Jobs Per Hour (JPH), and First Time Through (FTT) quality.
• Design and refine station layouts using CAD, incorporating tooling, material presentation, and error-proofing (Poka-Yoke) for zero-defect manufacturing.
• Conduct ergonomic job evaluations and implement workstation designs that meet high safety standards in automated, high-speed production environments.
• Manage procurement, commissioning, capability validation, and debugging of new production equipment, including vendor site buy-offs.
• Collaborate with Product Design, suppliers, and manufacturing teams to develop optimal process strategies, including gauging, torque strategies, and in-process testing.

Leadership & Culture

• Embrace the Gemba philosophy: Regularly engage on the production floor to identify bottlenecks, verify standardized work adherence, and solve problems in real time.
• Develop "Leaders as Teachers": Mentor Production and Operations teams on lean principles, including takt time vs. cycle time and waste elimination.
• Remove Barriers: Proactively mitigate risks in the launch phase to ensure seamless equipment buy-offs and successful Start-Of-Production(SOP).
• Proactive Problem-Solver: Catalyst who identifies gaps and proposes solutions before they become issues.
• Champion Transparency: Partner cross-functionally with Manufacturing Engineering, Quality, and Operations to achieve Ford Energy’s Vision, Mission, and Values.

Strategic Management & Integrity

• Establish and track Production Key Performance Indicators (KPIs), including OEE (Overall Equipment Effectiveness), scrap rates, and FTT quality.
• Lead cross-functional initiatives in quality to achieve "No Faults Forward" and zero defects on the production line.
• Coordinate quality containment actions, dock holds, and special checks to eliminate any impact on the customer, maintaining detailed traceability records.
• Manage quality documentation, including FTT, 8Ds, Scrap, and Dock Audits.
• Lead 8D root-cause resolution for warranty and battery operations concerns in collaboration with Quality, MP&L, and Assembly teams.
• Manage and direct statistical process control (SPC) activities, execute measurement systems analysis (MSA), and variable data analysis to drive process capability (Control Plans).
• Review rejected parts for quality integrity, determine corrective actions, and issue daily quality reports.
• Manage the Engineering Change Management (ECM) process for the production floor, ensuring all process modifications are documented, and process sheets/instructions are updated accurately.

Capabilities for Success

• Resilient leader: Demonstrates composure and sound judgment in a high-pressure startup production environment.
• Collaborative influencer: Builds trust and aligns cross-functional teams on production targets, labor standards, and workstation design.
• Throughput expert: Skilled in capacity modeling, bottleneck identification, and high-volume automated manufacturing.
• Integrity-focused: Upholds standardized work and engineering rigor, ensuring safety and quality are never compromised

You’ll have...

• Education: Bachelor’s degree in Engineering (e.g., Mechanical, Electrical, Chemical, Industrial, Manufacturing, or a related engineering field)
• Experience: 3-5+ years of progressive experience in Industrial Engineering or Manufacturing Engineering within a high-volume production environment.

Even better, you may have...

• Experience in Greenfield site development or high-volume automotive, battery, or electronics manufacturing.
• Lean Manufacturing and/or Six Sigma certification (Green Belt or Black Belt).
• Experience with 8D, 5-Why analysis, DMAIC/DMADV methodologies, and lean tools (5S, Kanban, Poka-Yoke, Value Stream Mapping).
• Familiarity with engineering change and release systems (e.g., WERS, CORA, or similar).
• Strong communication, collaboration, and team-building skills.
• Passion for energy systems and U.S. energy independence.
• Technical Knowledge: Advanced proficiency in AutoCAD, MODAPTS, and manufacturing simulation tools.
• Leadership Attributes
  • Strategic visionary: Translates production data into scalable manufacturing strategies aligned with the growing BESS industry.
  • Decisive under pressure: Makes rapid, data-driven decisions during line balancing and production ramp-up.
  • Adaptable: Leads effectively in an evolving startup environment and supports a 24/7 operation, including nights, weekends, and holidays as needed.
• Location & Travel
  • U.S. with domestic travel

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

This position is a salary grade 5 and ranges from $65,100-$109,300.
This position is a salary grade 6 and ranges from $74,300 -$124,500.
This position is a salary grade 7 and ranges from $86,600-$144,900.

Final determination of salary grade will be based on candidate's skills and experience, and base salary will be set within the applicable range according to job scope, responsibility and competitive market value.

Company: As Ford establishes a wholly owned subsidiary focused on Battery Energy Storage Systems, this role will initially be employed by Ford and is expected to transition to the subsidiary within one year.

Visa sponsorship is not available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire. We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660.