Senior Principal Diagnostics Engineering Manager

As the Senior Principal Diagnostics Engineering Manager, you will lead the strategy, development, launch, and continuous improvement of manufacturing diagnostics and end-of-line (EOL) testing capabilities for next-generation Ford vehicles.

Operating at the intersection of regional execution and global strategy, you will drive the operational readiness of all EOL test tools across our Africa and Asia Pacific assembly plants. Additionally, you will collaborate with and influence US-based engineering teams to ensure global feature development aligns with regional requirements and plant constraints, ultimately securing high-quality vehicle validation and manufacturing performance.

Reporting directly to the Manufacturing Technology Development Manager in the US, this new created position is based at our IMG Product Development Centre in Broadmeadows, Melbourne. This role operates under a hybrid work arrangement, requiring four days on-site.

Responsibilities

• Lead the development and deployment of manufacturing diagnostic strategies and end-of-line test processes for new vehicle programs.
• Drive launch readiness and operational strategy for all EOL test tools across the Africa and Asia Pacific regions.
• Ensure EOL test tools are implemented and supported in a way that reflects regional manufacturing requirements, plant operating models, and local constraints.
• Define requirements for plant diagnostic tools, test sequences, flashing processes, and validation methods used during vehicle assembly and final verification.
• Partner with manufacturing, quality, program, and engineering teams to ensure diagnostic and EOL solutions are aligned with production needs, launch milestones, and plant capability.
• Influence US-based feature development and product roadmaps to ensure regional requirements and operational constraints are built into future EOL test tool capability.
• Act as the key bridge between regional plant needs and central development teams, translating operational challenges into clear feature, process, and capability requirements.
• Drive readiness for vehicle launches by ensuring diagnostic tools, test stations, and plant processes are prepared, validated, and supported.
• Support issue triage and root cause analysis for plant, launch, and production concerns related to diagnostics, flashing, and end-of-line testing.
• Identify gaps in test coverage and diagnostic capability, and develop improvements that enhance defect detection, manufacturing quality, and plant efficiency.
• Standardize best practices for diagnostics and end-of-line testing across programs and plants, improving consistency, scalability, and operational effectiveness.
• Collaborate with service, quality, and engineering teams to ensure diagnostic strategies support both manufacturing needs and downstream vehicle supportability.
• Monitor and improve key performance indicators such as first-time-through rates, test effectiveness, downtime reduction, failure detection, and manufacturing yield.
• Provide technical leadership and mentorship to engineering and plant teams supporting diagnostics and end-of-line test operations.
• Support supplier and partner coordination related to diagnostic equipment, test systems, and manufacturing integration.
• Drive continuous improvement in diagnostic processes, test methods, tool usability, and problem-solving practices across the organization.

Qualifications

• Bachelor’s degree in Electrical Engineering, Mechanical Engineering, Automotive Engineering, Manufacturing Engineering, or a related technical field.
• 15+ years in automotive diagnostics, manufacturing test, end-of-line testing, or related vehicle validation environments.
• Proven leadership in defining and implementing complex diagnostic or manufacturing test solutions in high-volume automotive production settings.
• Deep understanding of automotive manufacturing processes, vehicle electrical systems, and end-of-line validation requirements.
• Strong experience with diagnostic tools, flashing processes, test equipment, and fault isolation methods used in vehicle assembly and final verification.
• Demonstrated ability to lead cross-functional collaboration across manufacturing, quality, service, product development, and program management teams.
• Proven expertise in root cause analysis, issue resolution, and structured problem solving in plant or launch environments.
• Experience supporting new vehicle launches, plant implementation, and production ramp activities.
• Experience working across global or regional manufacturing organizations, with the ability to balance central standards with local operational requirements.
• Strong knowledge of diagnostic performance metrics and manufacturing KPIs, with the ability to drive measurable improvements in test effectiveness, quality, and throughput.
• Excellent communication, stakeholder management, and leadership skills, with the ability to influence decisions across technical and operational teams.

Benefits

• Discounted lease car options.
• Multiple Employee Resource Groups – Ford Pride, Women of Ford and Ford Empowering Diverse Abilities.
• Flexible Work Arrangements.
• Growth and development opportunities via internal and external training.
• Paid parental leave from day 1.
• Comprehensive Employee Assist Program.
• Wellness Programs including Free Flu Vaccinations and Health Checks.
• Paid volunteer days.