Manufacturing Engineer – Battery Pack Assembly

The Manufacturing Engineer – Battery Pack Assembly is responsible for the technical development, implementation, and launch of battery manufacturing systems. This role follows the entire manufacturing value stream, from early product concept and feasibility through equipment runoff, plant installation, and final production launch. You will serve as a technical expert, integrating Ford manufacturing standards and digital tools to deliver safe, scalable, and cost-competitive battery solutions.

Responsibilities:

Manufacturing Process Development & Implementation

• End-to-End Execution: Lead the engineering of line layouts and implement manufacturing processes for assembly of battery packs.
• Early Feasibility: Provide technical manufacturing input during product concept phases to influence architecture, assembly feasibility, and scalability.
• Equipment Design & Buyoff: Collaborate with OEMs and automation partners to design manufacturing equipment and tooling. Lead on-site equipment buyoff per acceptance procedures.
• Plant Launch: Lead equipment installation and commissioning. Support plant operations through SOP (Start of Production) and the "Rate of Climb" phase to achieve OEE, cycle time, and JPH targets.

Simultaneous Engineering & Quality

• DFM (Design for Manufacturability): Drive simultaneous engineering with Product Development, Purchasing, and Suppliers to ensure products are optimized for high-volume manufacturing.
• Risk Mitigation: Lead the development of PFMEA (Process Failure Mode and Effects Analysis), Control Plans, and associated gauging/inspection requirements.
• Standards Compliance: Ensure all systems align with Ford BME standards, including MDS/MPS (Manufacturing Design/Process Standards) and Bill of Process (BoP).

Technical Pillars of Excellence

• Joining Technologies: Specify and validate joining processes, including fastening systems, adhesives/sealants, riveting, and specialty battery joining methods.
• Digital Manufacturing: Utilize digital tools and DPA5 workflows, including AutoCAD, TeamCenter, 3DX ,and Siemens PLM, for layout development, simulation, and virtual commissioning.
• Quality & Traceability: Implement vision systems, error-proofing, and data traceability solutions to ensure dimensional robustness and E2KS compliance.

Supplier & Project Management

• Technical Specifications: Develop Enquiry Specifications and provide technical support during supplier quoting and recap reviews.
• Change Management: Own the technical change management process to ensure Quality, Cost, and Timing targets are met.
• Documentation: Create detailed Manufacturing Instructions and drawings.

Qualifications

• Education: Bachelor’s degree in Engineering (Manufacturing, Mechanical, Industrial, Electrical, or related).
• Experience: 2+ years of manufacturing engineering experience in assembly or automation-intensive environments.
• Project Execution: Experience implementing specialized manufacturing lines or large-scale capital projects.
• Technical Tools: Proficiency in AutoCAD and experience with simulation or digital manufacturing tools (e.g., Siemens PLM, 3DX, TeamCenter).
• Communication: Strong verbal and written communication skills for interacting with suppliers and cross-functional teams.
• Mobility: Ability to travel and support on-site launches at manufacturing facilities.

Preferred Qualifications

• Master’s degree in Engineering.
• Specific experience in battery cell, module, or pack assembly processes.
• Strong understanding of GDT stack-ups and dimensional robustness.
• Proficiency in Joining Technologies (dispense systems, fastening, bolt feeders, welding).
• Experience with vision systems equipment and related error proofing.
• Knowledge of Machine Monitoring Systems and constraint analysis techniques.
• Familiarity with Ford BME governance, DPA5, and MDS/MPS standards.