STA Site Engineer

Socket.dev; Dearborn (MI); On-site; USD 84,000 - 162,000; Full time

Job summary

Ford Motor Company is seeking an experienced STA Engineer (Exterior) to industrialize and manage Quality, Capacity and delivery for exterior commodities at supplier sites, including injection molding, forming, and assembly, across BEV and ICE programs.

You will lead APQP/PPAP, drive PFMEA and Control Plans, coordinate with Ford and suppliers, and support new model launches and in-series production with travel within US/Canada/Mexico as needed.

Qualifications

• Bachelor of Science/Engineering or academic equivalent.
• Manufacturing/program management experience in industrial operations.
• Knowledge of stamping, molding, assembly and related processes.

Responsibilities

• Launch management with GPDS milestones to achieve flawless launches.
• Quality systems: PFMEA, Control Plans, PPAP, Q1-MSA compliance.
• Root-cause solving and continuous improvement with cross-functional teams.
• Capacity verification, risk mitigation and production attainment.

Skills

GD&T

Blueprint/CAD

Gage R&R

SPC

Six Sigma

Problem Solving

Education

Bachelor of Science/Engineering

Tools

APQP

PPAP

IATF 16949

Q1-MSA

SIM

Job description

We are looking for an experienced candidate to join our STA organization with effective communication, technical knowledge, project management, manufacturing, and process quality expertise in component parts production for Body Exterior commodities.

As a Supplier Technical Assistance (STA) engineer specializing in Exterior, you will be responsible for industrializing and managing "Quality" and "Capacity" of Exterior commodities at Tier 1 supplier sites — including injection molding, Blow molding, low-pressure molding, thermoforming, and final assembly operations — on new model program launches and in-series production.

In this position ...

Drive supplier manufacturing excellence, flawless program launches, and capacity assurance across assigned commodities. The role ensures supplier parts meet stringent quality, design, and rate requirements from pre-sourcing through mass production.

The candidate will work collaboratively within Ford and multiple supplier partners to launch Vehicle systems and commodities including body exterior and interior, vehicle and battery stampings and structures, frames, underbody, powertrain, and electrical for both Battery Electric (BEV) and Internal Combustion Engine (ICE) vehicles for Ford Blue and Model-e programs. The candidate will be responsible for industrializing and managing Quality, Capacity and resolving production delivery issues for new model programs launches and “in-series” production programs. Depending on your assigned supplier site locations, flexibility to travel within US/Canada and Mexico is required.

Responsibilities

What you’ll do ...

1. Launch Management & APQP / PPAP

• Lead supplier launch readiness per Global Product Development System (GPDS) milestones to achieve flawless launches and on-time “date to green” targets and optimized part pedigree.
• Review and approve supplier capital, tooling work plans, and end-item compliance through rigorous PPAP (Production Part Approval Process) and Run-at-Rate evaluations.
• Conduct onsite technical assessments and manufacturing feasibility evaluations for new sourcing and program integration.

2. Quality Systems & Failure Mode Avoidance

• Enforce robust defect prevention by driving, reviewing and approving PFMEAs, Control Plans, SCCAFs, Special Manufacturing Process Assessments, Manufacturing Health Charts and implementation of robust process controls.
• Apply Geometric Dimensioning and Tolerancing (GD&T) principles to verify part print feasibility, datum structures, measurement systems (Gage R&R), and process capability (SPC).
• Drive supplier adherence to special process requirements with Ford Technical Specialists and lead Q1-Manufacturing Site Assessments (Q1-MSA) for continuous site improvement.

3. Root-Cause Problem Solving & Issue Resolution

• Lead supplier process quality containment and permanent corrective actions for critical issues (QR, Stop Ship/Build, BSAQ, Field Actions).
• Champion structured Problem‑Solving methodologies (Global 8D, A3, 5-Why, Drill Down) to identify true root causes, implement robust error‑proofing, and migration of prevent recurrence which delivers measurable defect reduction (QR, PPM, TGW, R/1000, CPU, Warranty).
• Partner with cross‑functional teams to establish and monitor Continuous Improvement Action Plans (CIAPs).

4. Capacity Verification & Production Risk Mitigation

• Interface with Purchasing to conduct Global Capacity Planning (GCP) studies and validate supplier Capacity Analysis Reports (eCAR).
• Identify production bottlenecks, de‑risk manufacturing constraints, and oversee recovery plans for constrained supplier operations to ensure quality and production attainment.

Core Competencies & Key Skills:

• Technical Skills: GD&T (Geometric Dimensioning & Tolerancing), Blueprint/CAD interpretation, Tooling & Fixture validation, Gage R&R, SPC, and commodity‑specific manufacturing processes (stamping, molding, assembly, machining, etc.)
• Quality & Systems Expertise: APQP, PPAP, PFMEA, Control Plans, IATF 16949, Q1-MSA, SIM, and Lean Manufacturing principles.
• Problem Solving & Analytics: Structured Problem Solving (Global 8D, Six Sigma, Root Cause Analysis), data‑driven decision making, and risk assessment/mitigation.
• Program & Supplier Leadership: Cross‑functional collaboration, capacity/bottleneck resolution, supplier auditing, and driving accountability to recovery timelines).
• Launch & Industrialization: Manage greenfield/brownfield and new model launch programs capital, tooling and manufacturing planning.

Qualifications

You’ll have ...

• Bachelor of Science/Engineering or academic equivalent
• Manufacturing and/or Program Management experience in an industrial operations environment.
• Knowledge of manufacturing processes(es), tooling, and assembly of the responsible vehicle system & component commodities: body exterior and interior Class A trim and badging, vehicle and battery stampings and structures (Steel and Aluminum), frames, underbody, powertrain, and electrical assembly
• Experience with Tooling, Assembly, Stamping, welding, metal/plastic joining technologies, Injection Molding, Electronics Mfg., Painting, and/or Machining is desired
• Functional expertise in Problem Solving, Quality systems (ex. SIM, IATF) and tools
• Supply/Issue Resolution Management Experience
• Proficiency in English, both written and oral when working with global teams
• Flexibility to Travel

Even better, you may have:

• Advanced knowledge of the electronics manufacturing process with hands‑on experience
• Six Sigma Black Belt Certification: Demonstrated ability to lead quality improvements initiatives, apply Six Sigma philosophies and principles (including the DMAIC Model)
• Conducted Statistical Analysis and mentored other engineers
• Experience mentoring internal teams of Supplier Quality Engineers
• Experience Industrializing NEW Automotive Electronics Manufacturing suppliers in North America (Greenfield Sites) leading to on‑time PPAP approval.
• Experience in Ford's Phased PPAP and APQP Process and Deliverables
• Experience using AI in problem solving cases

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 the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, and prescription drug coverage
• Flexible family care, parental leave, new parent ramp‑up programs, subsidized back‑up childcare 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.

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 committed to a culturally diverse workforce. 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 a salary grade 7 and ranges from $84,480-141,360.

This position is a salary grade 8 and ranges from $96,720-162,120.

At Ford Motor Company, we believe freedom of movement drives human progress. With our incredible plans for the future of mobility, we have a wide variety of opportunities for you to accelerate your career and help us define tomorrow’s transportation.

Ford’s Purchasing team works to ensure that parts and services sourced from around the globe are of the highest quality, at optimal cost, and delivered on‑time. We aim to build strong relationships with the supply base so that Ford can produce vehicles that our customers want and value. Building and maintaining strong, mutually beneficial relationships with the supply base helps us lower costs, improve quality and make progress toward our sustainability goals. We recognize that a diverse supply base is an integral part of our overall success, providing fresh perspectives that lead to cutting‑edge innovations and accelerated business development. We continue to foster productive relationships with entrepreneurs from a wide range of backgrounds to meet our customers’ needs and expectations.