Program Body Vehicle Line Specialist

Be the first to apply for this exciting opportunity as a Program Body Vehicle Line Specialist at Ford Motor Company. As a key member of our team, you will play a crucial role in leading a team of core manufacturing engineers in planning and execution phases of new model programs.

Key Responsibilities:

• Lead team of core manufacturing engineers in planning and execution phases of new model programs
• Accelerate process needs into overall strategy plan to support plant requirements, integrate teams for collaboration and track open issue resolution
• Deliver facility, tooling, and quality systems and launch new model programs

Responsibilities:

• Review master sections
• Support feasibility reviews
• Provide cross-carline experience to implement lessons learned and adhere to best common practice guidelines
• Assist in defining new program assumptions and achieve best-in-world quality based on prior vehicle experience
• Ensure GAP/BEST PRACTICES/GMR/DESIGN RULES/PDPD/CETPs are followed
• Power wall/clay reviews verify fit and finish match SRI targets and requirements
• Ensure product design is robust and will prevent misbuilds, misloads, or other manufacturing issues ensuring that engineering line rates can be achieved
• Identify and develop action to prevent knifing or shingling conditions
• Ensure locator commonality and part orientation through gages tools etc. - including outside part suppliers
• Support virtual formability studies ensure stamping parts are manufacturable
• Predict and establish measuring points and tolerances using DVA, LD standards, and engineering judgement
• Structures approval digitally and physically sign off designs and EI changes
• Design compatibility reviews
• Review interface with trim, chassis ensure bodyshop requirements are deliverable or drive modifications to trim/chassis components to ensure they are less sensitive to sheetmetal variation
• Cut sections to release product to verify weld feasibility, fit/finish, cheats, metal thickness, clearances, and flat for sealer, weld flange length, weld gun access, slip planes, interferences, product, and process compatibility cheats
• Review component and assembly design with suppliers
• Assist in development/use of data control model (DCN) and adjustable craftsmanship models
• Order parts and follow up for PCF
• Ensure all diagnostic gages follow build process
• Ensure sensitivity analysis is performed on areas of concern and that recommendations are accepted
• Development of all dimensional control plans in bodyshop (labor/CMM/capacity etc.)
• Lead layout of CMM and dimensional control areas
• Assist in the development of quality roadmaps (TGW, R/100, and warranty reduction plans)
• Monitor product quality indicators and assure that appropriate actions are incorporated into the new model
• Verify that product design meets standards for margin and flushness (flushness of one line in side view, minimized skewed cutlines, overcrowns, door cheats, hood cheats, laserwelding cheats, nose to fender cheats)
• Review cube and snapshot models (white room) for craftsmanship items to ensure 'best in world' delivery of exterior with all anticipated variances
• Ensure issues identified in FC reviews are monitored and driven to resolution
• Verify design compatibility between all sheetmetal components, assist in the design compatibility of other components that interface to sheetmetal (chassis, trim)
• Act as the manufacturing and assembly representative in all structures reviews providing feedback on preferred designs
• Lead the measuring point selection process to assure adequate dimensional information is taken and to assure measuring points are coordinated between adjacent panels and support needed diagnostic for trim/chassis and ext ornamentation
• Ensure that assembly plant layout and pullout stations are adequate to support a solid dimension control inspection frequency
• Ensure that scheduling is given PCF vehicle specs and that the units are scheduled
• Ensure that PPM is delivered the PCF1 and 2 BOM and that the BOM is validated for all columns (production supplier, quantity, part etc) utilizing the 'How to pull your own GPIRS BOM' presentation
• Responsible to ensure the accuracy of the DCD costing for assigned program
• Support and lead LD meetings with respective manufacturing engineer for assigned program
• Support and lead MP drawings meetings with respective manufacturing engineer for assigned program
• Approve gage/fixture design concept and 100% design meetings and sign off all fixtures
• Update PCF executive summary on weekly basis
• Review all DCD program scoping documents to ensure scope is sufficient to meet demands of the program and are optimized for cost and quality
• Develop the pre-launch control plan ensuring the frequencies and sub-assemblies to be checked are adequate to support the bodyshop proforma and deliver a best-in-world vehicle
• Assist the dimensional control engineer with creating the production control plan and ensure that frequencies and checks are adequate to ensure best-in-world delivery for ongoing production. Coordinate the approval of said process through the dimensional control dept manager for signoff
• Ensure locator consistency through tools and gages
• Ensure design rules, GMR, SDS, PDPD compliance
• Utilize pre-TT build events (DCV or VP/CP) to schedule and execute an effective emphasis build
• Ensure that all products will deliver best-in-world attributes (wind/water leaks/air leakage/fit/function/efforts)
• Perform simple RSS studies and validating and work with DVA for more complicated geometrical studies - ensure that ongoing normal variability will not effect SRI, manufacturability, downstream customer concerns, wind/water etc...
• Support final assembly by reviewing the GD&T assumptions and gage assumptions on exterior ornamentation to ensure strategy replicates how the parts see the vehicle and ensure that they will deliver best-in-world fit and function
• Provide the voice of the customer for sheetmetal related items and key interfacing areas
• Support all virtual builds and DPA events
• Support all feasibility discussions
• Ensure fit and finish through SRI development
• Ensure carryover part issues build issues and capability issues that may affect the new model launch are corrected or addressed or have established workplans to resolve
• Ensure that PCF metal is ordered correctly and on time
• Validate PCF BOM and work with PPM to correct as required
• Support the bodyleader by managing the VTTO requirements and ensuring that the pilot plant and suppliers deliver material as promised and have the builds scheduled on their master schedule
• Lead manufacturing-driven product feasibility rejections
• Ensure design gaps and slip planes are properly engineered
• Ensure product meets MDS, SDS, PDPD, DPA checklists
• Ensure product meets all welding requirements and drive resolutions (flange lengths, joint designs, gun clearance, thickness ratios, etc)
• Participate in DFMEA/PFMEA meetings
• Participate in tooling design reviews
• Sign off and ensure all supplier gages follow recommended practices, have no RFS pins, and are adequate to ensure that only quality supplier parts will be shipped to Ford Motor Company

Requirements:

• Bachelor's degree in mechanical engineering or related field
• 5+ years of experience in automotive manufacturing or related field
• Strong knowledge of automotive manufacturing processes and procedures
• Excellent communication and problem-solving skills
• Ability to work effectively in a team environment
• Strong analytical and technical skills
• Ability to work under pressure and meet deadlines
• Strong attention to detail and ability to maintain high level of accuracy
• Ability to travel as required

Preferred Qualifications:

• Master's degree in mechanical engineering or related field
• 10+ years of experience in automotive manufacturing or related field
• Experience with lean manufacturing principles and practices
• Experience with Six Sigma methodologies
• Experience with design for manufacturability (DFM) and design for assembly (DFA)
• Experience with computer-aided design (CAD) software
• Experience with computer-aided manufacturing (CAM) software
• Experience with enterprise resource planning (ERP) software
• Experience with product lifecycle management (PLM) software
• Experience with data analytics and statistical process control (SPC)
• Experience with quality management systems (QMS)
• Experience with regulatory compliance (e.g. ISO 9001, IATF 16949)
• Experience with continuous improvement methodologies (e.g. Kaizen, Lean)

Salary: $120,000 - $150,000 per year Benefits: Comprehensive health insurance, 401(k) matching, paid time off, and professional development opportunities Work Schedule: Monday - Friday, 8am - 5pm Location: Dearborn, MI Travel: Up to 20% of the time Security Clearance: None required Relocation Assistance: Available for qualified candidates Equal Employment Opportunity: Ford Motor Company is an equal employment opportunity employer and welcomes applications from diverse candidates.