Process FMA Engineer

Lincoln Motor Company; Dearborn (MI); Hybrid; USD 74,000 - 166,000; Full time

Benefits offered by this job

Medical, dental, vision coverage

Flexible family care days

Vehicle discount program

Tuition assistance

Paid holidays and PTO

Job summary

Ford Motor Company is seeking a Powertrain Manufacturing Engineering professional to drive quality robustness across PTME, coaching launch teams and collaborating with Global Quality. You will update QOS, standard documents, and lead continuous improvement initiatives.

The role emphasizes FMA deliverables (PFMEA, Control Plans), problem-solving, and launch/warranty support with travel to plants as needed.

Qualifications

• Bachelor of Applied Science in Engineering with 5+ years in manufacturing engineering.
• Experience in APQP, PFMEA development, and Control Plans.
• Strong leadership, analytical, and structured problem-solving skills.

Responsibilities

• Develop, review, and maintain PFMEAs and Control Plans to align with standards.
• Support root cause analysis and PCA/PRA using structured tools (3L5Y, 8D, A3).
• Lead launch quality reviews and warranty deep-dives to identify recurring issues.

Skills

Leadership

Analytical thinking

Structured problem solving

Communication & coaching

Teamwork & flexibility

Self-motivation & agility

Education

Bachelor of Applied Science in Engineering

Tools

PFMEA

Control Plans

3-Legged 5-Why (3L5Y)

Ford Quality Operating System (QOS)

AutoCAD / CAD tools

Job description

We made history and now we work to transform the future - for our customers, our communities and our families. You'll see your work on the road every day, helping people move freely and pursue their dreams. At Ford, you can build more than vehicles. Come build what matters.

As part of our Manufacturing team, you'll help build the world-class, state-of-the-art smart vehicles we're known for. In our plants around the world, we're constantly developing new technologies and processes to further increase our efficiency. You'll get the satisfaction of making great products people use and love.

The Powertrain Manufacturing Engineering (PTME) Process Failure Mode Avoidance (FMA) and Prevent Recurrence Team is seeking a motivated professional to drive quality robustness across our engineering factory. Leveraging expertise in FMA deliverables including PFMEAs, Control Plans, error-proofing strategies, engineering standards, and new program launch requirements; you will support PTME launch teams through coaching, training, technical deep dives, and enhancements to engineering standards. Additionally, you will collaborate with global teams to resolve powertrain launch quality concerns and execute continuous improvement initiatives.

Work directly with PTME and Global Quality teams to improve the Quality Operating System (QOS), update standard documents, enhance FMA process robustness, and lead continuous improvement training initiatives. Key responsibilities include:

• FMA & Quality Deliverables: Assist in the development, review, and maintenance of Process FMA deliverables—including PFMEAs and Control Plans to ensure alignment with corporate standards.

• Problem Solving & Root Cause Analysis: Support root cause analysis and permanent corrective action (PCA/PRA) processes using structured problem-solving tools such as 3-Legged 5-Why (3L5Y), 8D, and A3.

• Launch & Warranty Support: Conduct launch quality and warranty deep-dive reviews; to help identify recurring failure modes, risk areas, lessons learned, potential systemic improvements and ultimately support warranty reduction workstreams.

• Lessons Learned & Best Practices: Collaborate with cross-functional partners (Product Development, Plant Quality, and Global Engineering) to support the development and implementation of best practices, drive continuous improvement and issue resolution document and cascade Quality Operating System (QOS) lessons learned into forward-model programs.

• Continuous Improvement & Audits: Support the update and enhancement of FMA tools, training materials, and ISO audit compliance activities across manufacturing engineering, including DRIM (Departmental Records Inventory Matrix) maintenance.

• Plant Support & Travel: Travel to Powertrain Manufacturing Plants as required (including occasional overnight stays) to support launch teams, deep dives, and plant quality initiatives.

Note: Training will be provided for the above responsibilities and associated systems as needed.

Minimum Qualifications:

• Education & Technical Experience: Bachelor of Applied Science in Engineering degree (or equivalent) with a minimum of 5 years of experience in a manufacturing engineering discipline.

• Plant & Quality Background: Proven manufacturing and quality experience in a plant manufacturing environment, including direct experience in APQP (Advanced Product Quality Planning), PFMEA development, and Control Plans.

• Problem Solving & Analytics: Strong leadership, analytical, and structured problem-solving skills paired with an innovative, continuous improvement mindset.

• Communication & Coaching: Excellent verbal and written communication skills with the ability to teach, coach, and effectively present technical materials to peers and various levels of PTME leadership.

• Teamwork & Flexibility: Strong interpersonal skills with a proven track record of collaborating effectively within diverse, dynamic, cross-functional teams.

• Self-Motivation & Agility: Fast learner with self-motivation and initiative to proactively acquire technical knowledge independently via online documents and cross-functional networking to master complex data and processes.

Preferred Qualifications:

• Ford Quality Systems Expertise: Demonstrated technical knowledge of Ford Quality Processes, such as Ford Quality Operating System (QOS), Process FMA (SCCAF/SCCP, FMEA, Control Plans), Bill of Process (BOP), Quality Launch Readiness Assessments, 3-Legged 5-Why Problem Solving, Six Sigma, and Global 8D methodologies.

• Six Sigma Certification: Six Sigma Green Belt or Black Belt certification.

• Core Ford Systems Knowledge: Familiarity with Ford Core Engineering Systems such as MIDAS, FEDE, Global Manufacturing Requirements / Knowledge Packets, engineering standards, and GPDS powertrain deliverables.

• Technical & CAD Tools: Familiarity with Computer Aided Drafting (CAD) tools (e.g., AutoCAD) and GD&T knowledge.

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder...or all of the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, vision and prescription drug coverage

• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up childcare and more

• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more

• Vehicle discount program for employees and family members and management leases

• 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 range of salary grades 6-8 and ranges from $74,300-$166,200.

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.

Visa sponsorship is not available for this position.

Domestic relocation is 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.

This position is hybrid with a requirement to be onsite four or more days per week.