Senior Suspension Structural Design & Manufacturing Expert

Ford Motor Company; Augusta (ME); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Vehicle discount program for employees

Tuition assistance

Paid time off

Holidays

Family care benefits

Job summary

Ford Motor Company seeks a Technical Expert (LL6) to lead the design, development, and in-house process delivery for suspension structural components across stamping, casting, and forging. You will drive design for manufacturability, process simulations, and rigorous DFMEA/PPAP practices to ensure production readiness.

Responsibilities include leading in-house process development, APQP planning, and cross-functional collaboration with suppliers and internal teams; travel to plants and global

Qualifications

• BS in Engineering is required.
• Extensive experience in chassis structural design and engineering.
• Experience with DFMEA, PFMEA and related quality tools.
• Proficiency with GD&T and drawing practices.
• Knowledge of DOE and process optimization methods.
• Experience with root cause analysis and problem solving.

Responsibilities

• Lead the development and delivery of an in-house design and manufacturing process for suspension structural parts (stampings, castings, forgings).
• Develop and maintain internal engineering foundation documents including design guides, design rules, requirements, and interface contracts.
• Create and manage Level 2 technical materials including Process FMEAs, Control Plans, Safe Launch Control Plans, and Sub-component BOMs.
• Lead DFMEA/FMEA and DFA reviews prior to tool kickoff and ensure designs meet tool and plant constraints.
• Drive in-house manufacturing process simulations to optimize structure and feasibility.
• Lead OK to tool processes with suppliers including steel purchase approvals and finishing steps.
• Conduct facility correlation studies to validate structure at Ford test facilities and supplier locations.
• Develop component and assembly GD&T for in-house designs and sign-off prints for structural parts.
• Support prototype development with program teams on parts.
• Manage data collection and capability analysis for SC/CC, calculating Ppk for pre-production/production.
• Lead process optimization trials and DOE to confirm manufacturing improvements.
• Develop APQP plans and conduct OK-To-Build/OK-To-Ship reviews; oversee gauge and fixture design sign-offs.
• Lead root cause analysis (8D, JIRA) for dimensional, processing, and manufacturing quality issues during launch, DV/PV testing, and production.

Skills

Chassis structural design

DFMEA / PFMEA

GD&T (advanced)

DOE / process optimization

Root cause analysis

Education

BS in Engineering

Tools

CAE tools

Manufacturing simulation software

Job description

Ford Motor Company seeks a Technical Expert (LL6) to lead the design, development, and in-house process delivery for suspension structural components across stamping, casting, and forging. You will drive design for manufacturability, process simulations, and rigorous DFMEA/PPAP practices to ensure production readiness.

Responsibilities include leading in-house process development, APQP planning, and cross-functional collaboration with suppliers and internal teams; travel to plants and global