Site STA - Underbody

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 Underbody commodities.

As a Supplier Technical Assistance (STA) engineer specializing in Underbody, you will be responsible for industrializing and managing "Quality" and "Capacity" of Underbody commodities at Tier 1 supplier sites , including Transmission Components (Springs, Washers, Bearings, Valves, Gears and Gear Blanks), Forging, Casting, Sintering, Machining, Assembly, Heat Treatment, Coating, Welding, Riveting, Joining, and Gaging of complex transmission component assemblies and assorted end items including metals, hinges and plastics.

Responsibilities

• 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.

• 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.

• 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).

• 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.

Qualifications

• Minimum:
• Bachelor of Science/Engineering or academic equivalent
• Manufacturing and/or Program Management experience in an industrial operations environment.
• Knowledge of manufacturing processes(es), castings, forgings, sintered components, cutting tooling, and assembly of the responsible vehicle system & component commodities: Transmission components and underbody components, vehicle and battery forgings, castings, stampings and structures (Steel and Aluminum), frames, underbody, powertrain, and electrical assembly
• Experience with Forging, Casting, Sintered process, Machining, Cutting Tools, Assembly, Stamping, welding, metal/plastic joining technologies, Injection Molding, Electronics Mfg., Painting, and Machining is desired
• Functional expertise in Problem Solving, Quality systems (ex. SIM, IATF) and tools
• Preferred:
• Advanced knowledge of the 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 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

Benefits

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, 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.