About this role
Ford Motor Company
The Inverter Process Engineer Serving as the key technical interface between Product Development, Manufacturing Process Development (PTME), and the manufacturing floor, the Process Engineer translates complex technical information and engineering changes into clear, visual, and actionable manufacturing standards, through proactive identification and elimination of process waste, ergonomic risks, and technical bottlenecks, the Process Engineer helps ensure that the Inverter line maintains the technical reliability, process capability, and standardized tooling required to consistently achieve SQDCPME objectives.
The role also serves as the technical subject-matter expert for selective soldering processes, including visual process confirmation on the manufacturing line.
Safety Culture Leadership and Prevention of Unsafe Acts:
Demonstrate and promote awareness and application of the plant’s Safety Values.
Proactively identify, correct, and prevent unsafe acts and conditions in the work area, fostering a strong culture of safety awareness and personal accountability within the team.
Process Observations (SOI) and Incident Investigation (OSHIM - GPA)
Ensure completion, compliance, and analysis of Safety Observation Index (SOI) observations across the assigned production lines.
Participate in incident and accident investigations following the methodologies and platforms established by the global management system, including OSHIM - GPA.
Engineering Change Management Support to the Process Engineer in Specification Changes:
Starting at Launch, maintain awareness of the latest product engineering levels through Change Control. Participate in part sign-off upon receipt of initial materials and ensure the Inverter process launches with the latest engineering level of all applicable parts, from EPT and PTRs through the entire product lifecycle.
Change Control: Review, approve, and implement engineering changes through key systems (SOLVE-JIRA, WERS, MTC, DCP), maintaining close coordination with Product Development (PD), leading DCP meetings, and participating in MTC meetings.
Process Control, Stability, and Capability
Capability Analysis: Conduct periodic monthly and annual process capability studies and reports (Cp/Cpk and Pp/Ppk) to ensure the stability and capability of CC and SC process characteristics.
Parameter Control: Adjust equipment parameters and review control documentation (PFMEA, engineering/design drawings, DCP, Parameter Sheets) in coordination with Product Development (PD), Production, and Quality to maintain the process under control.
Reaction Plans: Develop, execute, and communicate clear and effective reaction plans for process deviations or out-of-control conditions.
Ensure proper calibration of master parts and related equipment used for torque measurement.
Problem Solving and Customer Support
Customer Complaints: Respond with a sense of urgency, within the first 24 hours, to complaints from internal customers (Assembly), external customers, Vehicle Operations (VO) assembly plants, and Warranty.
Root Cause Analysis: Lead investigations of major quality issues in collaboration with PD, Production, Quality, and Suppliers, applying structured problem-solving methodologies such as RCA, G8D, and DMAIC to prevent recurrence and quality escapes.
Non-Conforming Material Control: Identify, contain, and manage suspect or defective parts through applicable systems (QLS, CMMS), ensuring proper follow-up of quarantined material, with a maximum quarantine period of 15 days.
Defect Monitoring: Monitor defect trends affecting Assembly, measured in R/1000, and define appropriate containment actions.
Technical Documentation Management
Maintain knowledge and proficiency in the procedures applicable to the assigned process, including PTO, Corrective Actions, Welding, Inspections, and PFMEA.
Document Maintenance: Create, update, release, and obsolete operational and process documentation, including DCP, PFMEA, Visual Aids, Process Sheets, QPS, Quality Alerts, Lessons Learned, and other applicable documents.
Version Control: Ensure the latest revision of all applicable documentation is available and up to date within the system.
Data Management: Ensure proper management of departmental records and reports in accordance with GIS1 and GIS2 requirements.
Metrics, Continuous Improvement, and FPS Adherance Agent
Process Optimization: Implement and sustain Lean Manufacturing tools and methodologies, including Kaizen, 5S, Value-Added/Non-Value-Added (VA/VNA) Analysis, TDM, standardization, VSM, Poka-Yoke, Error Proofing, and other applicable tools (POKAR)
Performance Indicators as a Quality and Maintenance support: Monitor, analyze, and improve key performance metrics, including scrap, quarantines, rejects, FTT, RTY, FRC and TTP and RCA.
Audits, Compliance, and Cross-Functional Collaboration including Data-Driven Corrective Action Management
Quality Management Systems: Ensure compliance with and readiness for audits against applicable automotive industry standards and requirements, including ISO 9001:2015, IATF 16949, WHTX, ISO 14001, and CQI-9, while leading the systematic closure of audit findings.
Quality and Process Audits: Actively participate in cross-functional quality audits (QOS), process mapping (QCM), and contamination control activities (Dirt Check POS & POU).
Information Flow (QOS/TDM): Participate in QOS meetings together with the Quality Engineer to ensure proper review and follow-up of critical issues.
Together with the Quality Engineer, perform a weekly analysis of the Top 3 detractors impacting key process indicators, including FTT & RTY, Scrap, Contamination, and Process Capability, to prioritize and focus improvement efforts.
Process Audits: Manage and execute the weekly process audit schedule to ensure operational discipline and compliance with manufacturing standards.
Quality Forums (DCC/PCC/BCC): Lead, prepare, and follow up, in collaboration with the Quality Engineer, on deliverables and metrics required for the weekly QOS meeting.
ICA / PCA Actions: Develop and implement Interim Containment Actions (ICA) and Permanent Corrective Actions
Bachelor’s degree in Mechanical, Electromechanical, or related Engineering field.
Minimum of 4 years of experience in automotive electronic component manufacturing, with hands-on experience supporting automated manufacturing processes and equipment.
Previous experience in Process Engineering, Process Coach, or similar process-focused manufacturing roles.
Working knowledge of automated vision inspection systems and soldering processes, particularly selective soldering, is highly desirable.
DISCLAIMER: Ford Motor Company is an Equal Opportunity Employer, as we are committed with a diverse workforce, and do not discriminate against any employee or applicant for employment because of race, color, sex, age, national origin, religion, sexual orientation, gender identity and/or expression, status as a veteran and basis of disability.