Technical Expert – Suspension Structural Component Design

Jobtailor; Dearborn (MO); On-site; USD 120,000 - 180,000; Full time

Job summary

Jobtailor is seeking an experienced Automotive Suspension Engineer to lead the in‑house design and manufacturing of suspension components for stamping, casting, and forging parts. You will own DFMEA, PFMEA, Control Plans, and APQP activities, driving process simulations to validate manufacturability.

Collaborate with cross‑functional teams and suppliers, guiding system‑level integration of active suspension technologies including ECU and sensor interfaces; 10+ years of experience required.

Qualifications

• BS in Engineering is required.
• 10+ years in automotive suspension engineering.
• Experience with DFMEA, PFMEA, Control Plans and GD&T.
• Launch experience with suspension components.
• Strong leadership and communication skills.
• Ability to coordinate with suppliers and senior leaders.

Responsibilities

• Lead development of in-house design and manufacturing process for suspension 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: Process FMEAs, Control Plans, Safe Launch Plans, and sub-component BOMs.
• Lead DFMEA, PFMEA, SCCAF, Control Plans, and GD&T drawings.
• Drive manufacturing process simulations to optimize structure and feasibility.
• Lead system-level integration of active suspension systems, ECU development, and sensor interfaces.
• Perform root cause analysis (8D, JIRA) for issues during launch and production.
• Develop APQP plans, OK-to-Build/OK-to-Ship reviews, Gauge R&R sign-off.

Skills

Automotive suspension engineering

Root cause analysis

DOE / Design of Experiments

Cross-functional leadership

Communication with leaders & teams

Project management

Education

BS in Engineering

Tools

CAE tools

Manufacturing simulation software

Teamcenter

WERS

Buck environments

Job description

Responsibilities

• Lead the development and delivery of an in‑house design and manufacturing process for suspension structural parts (stampings, castings, forgings), internalizing responsibilities
• Develop and maintain the Suspension Structural Component internal engineering foundation documents including design guides, design rules (DR’s), Requirements (RQTs), and interface contracts/agreements
• Create and manage Level 2 technical materials including Process FMEAs, Control Plans, Safe Launch Control Plans, and Sub‑component BOMs
• Lead Design for Manufacturing (DFM) and Design for Assembly (DFA) feasibility reviews prior to tool kickoff, ensuring designs align with tool design specifications, plant equipment compatibility, and normal process capability limits
• Drive in‑house manufacturing process simulations (e.g., stamping formability, casting solidification, forging flow) to optimize structure and ensure manufacturing process feasibility
• Lead OK to tool process with BTP supplier including approving steel purchase, OK to rough cut, and OK to finish steps
• Conduct test facility correlation study between Ford test facility (DV) to BTP supplier facility (PV) to ensure proper validation of the structure per core ES at both locations
• Develop component and assembly GD&T for in‑house designs and sign‑off program prints for BTP structural parts
• Support prototype development process with program teams on BTP parts
• Manage the data collection and capability analysis for Significant/Critical Characteristics (SC/CC), calculating Ppk to ensure pre‑production and production capability requirements are met
• Lead demonstrable process optimization trials and Design of Experiments (DOE) to confirm manufacturing processes are optimized
• Develop comprehensive APQP plans, conduct OK‑To‑Build and OK‑To‑Ship reviews, and oversee Gauge R&R trials, including the review and sign‑off of gauge and check fixture designs
• Lead root cause analysis and problem resolution (8D, JIRA) for dimensional, processing, and manufacturing quality issues during launch, DV/PV testing, and production
• Lead System‑Level Integration: Direct the system‑level development and integration of advanced active suspension systems, including ECU development, sensor integration, and electronically controlled dampers
• Technical Specification & Design Control: Define system design guidelines, perform rigorous specification reviews, and author system‑level Design Failure Mode and Effects Analysis (DFMEA) covering signal I/O, control modes, and hardware/software interfaces
• Chassis Technology Roadmap Alignment: Guide the development of next‑generation chassis technologies, including active dampers, air springs, and electronic roll control systems, ensuring alignment with future vehicle architecture glidepaths

Requirements

• BS‑Engineering required
• 10+ years of experience in automotive suspension engineering
• 6+ years of experience with design specific suspension components and commodities
• Extensive component engineering design and release experience in suspension structural components (stampings, castings, forgings), including specific experience on launch
• Deep understanding of Build‑to‑Print Supplier (BTPS) deliverables and the proven ability to execute manufacturing, tooling feasibility, and PPAP requirements in‑house
• Extensive experience creating and managing DFMEA, PFMEA, SCCAF, Control Plans, and drawings with advanced GD&T
• Experience with CAE tools, manufacturing simulation software, and process optimization methodologies (DOE)
• Strong analytical, math, and problem‑solving skills to lead root cause analysis for complex manufacturing and dimensional issues
• Understanding of GPDS deliverables and basic Ford engineering tools including Teamcenter, WERS, and buck environments
• Required leadership skills – quality‑focused as #1 priority, innovative, excellent communicator, strong organizational skills, highly motivated self‑starter
• Ability to handle complex tasks and challenging situations under compressed timing
• Experience communicating with senior leaders, design and release, manufacturing, and tooling suppliers
• Outstanding planning, organizational, and project management skills with proper follow‑up to accomplish multiple objectives
• Strong One Ford Leadership Behaviors with a demonstrated ability to drive and deliver results
• Ability to build strong effective relationships with cross‑functional teams (Foundation Chassis, Design and Release, Vehicle Operations, Testing Centers, and Suppliers)

Certifications & Qualifications

• BS in Engineering