Key responsibilities include leading the development of new composite manufacturing processes, defining and executing process development plans, and driving process maturation through programme gateways. The successful candidate will also lead Design for Manufacture (DFM) activities, ensure component designs are optimised for composite manufacturing processes, and provide early-stage manufacturing input during concept and design reviews.

Additionally, the Process Engineer will plan and deliver structured trials, DOEs, and validation activities to characterise process capability and performance. They will analyse trial data to establish process windows, understand sensitivities, and de-risk manufacturing routes. The Age will also support pilot builds and pre-production runs, ensuring processes are stable and repeatable before production release.

In this role, you will own the handover of new processes into production, ensuring all documentation, training, and controls are in place. You will define standard operating procedures, control plans, and key process parameters to ensure consistent production performance. You will also provide technical support during initial production ramp-up, resolving early-life issues and embedding process stability.

To succeed in this position, you will need a background in engineering or relevant hands-on experience in manufacturing, with experience or understanding of composite materials and manufacturing processes. You will also need exposure to developing and trialling manufacturing processes, the ability to work with engineering drawings, CAD data, and technical specifications, and experience collaborating with design and cross-functional teams.

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Key responsibilities include:

• Leading new/forward model product development of the base engine sub system for new engine platforms
• Designing, developing, and releasing components
• Leading/supporting resolution of major design, manufacturing, program, and launch issues
• Creating, completing, and approving supplier and Ford engine DVPs and overseeing testing in support of robust validation
• Leading Sub System CPMT activities
• Supporting all program meetings (EPMT, Design Review, DPMT, change control, etc.)
• Leading drawing release and changes
• Interfacing with Calibration, mating components, Purchasing, suppliers, and mfg./assembly plants
• Prototype Build coordination: loading forward model part numbers into system and ensuring fit and function
• Working directly with suppliers, Supplier Technical Assistance (STA), and launch teams to support programs and resolve quality issues, including travel both domestic and international when required
• WERS (Worldwide engineering release system) coordination; alerts, Concerns and SREA processing
• Developing and maintaining CPMT documents, including appropriate quality documents (ESOW, DFMEA, FEDE, e3P, SCCAF’s, Global Integrator, OPTEX, PPAP & PSW’s, 543 Chart etc.) for program specific sub-system responsibilities
• Creating, completing, and approving supplier and internal DV/PV test plans and overseeing testing in support of robust validation
• Leading/supporting warranty reduction and issue resolution using a structured 8D documented approach
• Leading/supporting TVM cost reduction idea generation and implementation
• Leading/supporting change control activities
• Traveling as necessary to Ford Assembly Plants/Facilities and Supplier/Sub-Supplier sites for issue resolution and build support

You'll have a Bachelor of Science in Engineering or related degree, or a combination of equivalent experience and education. You'll need 5+ years of Component and System/Subsystem D&R Experience, internal combustion engine experience preferred. You'll also need to be able to work effectively and lead in a team environment, have knowledge of FMEA’s, Control Plans, and DV/PV Plans, and possess basic knowledge of NVH, Materials, Durability, and Manufacturing processes.

Even better, if you have technical expertise/experience with Diesel internal combustion engines, specifically base engine design and release, experience with Ford internal PD systems (GPDS, FEDE, WERS, AIMS, SREA, Teamcenter, 3DX, Etc.), Green Belt certification (or black belt), base engine testing, 1D & 3D simulation methodologies – Both and Static and Dynamic, base engine Sub-system design & development, NVH - Noise Vibration & Harshness, Design for manufacture, and knowledge of Ford Motor Company’s Global Product Development System and design release process.

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