Ford Motor Company is Hiring | Manufacturing Process Engineer |

Position – Manufacturing Process Engineer- Powertrain
Company – Ford Motor Company
Location – Chennai, Tamil Nadu, IN

Job description

Required Skills

• Technical Expertise: In-depth knowledge of powertrain systems (ICE, Hybrid, or EV) and modern assembly technologies (e.g., DC nutrunners, press-fits, leak testing, vision systems).
• Quality Systems: Strong proficiency in APQP and PPAP processes. Expert-level understanding of PFMEA, SPC, and Control Plans.
• Data-Driven Decision Making: Advanced proficiency in data analysis using Excel and statistical software (e.g., Minitab or JMP) to track process capability (Cp/Cpk).
• CAD & Simulation: Proficiency in CAD software (SolidWorks, CATIA, or AutoCAD) for fixture design and workstation layout. Familiarity with process simulation software is a strong plus.
• GD&T: Strong ability to interpret complex engineering drawings and apply Geometric Dimensioning and Tolerancing.
• Project Management: Proven ability to manage multiple projects simultaneously, meeting strict deadlines and budget constraints.
• Communication: Excellent interpersonal skills with the ability to present technical data to senior leadership and collaborate with global teams.

Additional Skills/Experience

• Six Sigma Green Belt or Black Belt certification.
• Experience with Industry 4.0 technologies (IIoT, data automation, or robotics).
• Hands-on experience with PLC logic or automated assembly systems.
• Experience in a high-volume manufacturing environment with a focus on “Right First Time” quality.

Qualifications

• Education: Bachelor’s degree in mechanical engineering, Manufacturing Engineering, Automotive Engineering, or a related technical field.
• Experience: 2-5 years of professional experience in an automotive manufacturing environment, specifically focused on powertrain or complex mechanical assembly.

Key Responsibilities

• Process Design & Implementation: Lead the development, optimization, and standardization of powertrain assembly processes for engines, transmissions, and electrified drivetrains.
• Operational Excellence: Drive initiatives to enhance efficiency, reduce cycle times, and minimize scrap. Take ownership of Overall Equipment Effectiveness (OEE) improvements through data-driven analysis.
• Advanced Problem Solving: Lead Root Cause Analysis (RCA) for complex production issues and quality escapes using structured methodologies (8D, 5 Whys, Fishbone). Implement robust permanent corrective actions.
• Cross-Functional Leadership: Act as the primary manufacturing engineering liaison between Product Design, Quality, and Production teams to ensure seamless New Product Introductions (NPI).
• Documentation & Compliance: Author and approve Standard Operating Procedures (SOPs), Work Instructions, Process Flow Diagrams, and PFMEAs. Ensure all control plans are strictly followed and updated.
• Lean & Six Sigma: Lead Lean Manufacturing projects, including Value Stream Mapping (VSM), 5S audits, and Kaizen events to eliminate waste on the assembly line.
• Equipment & Tooling Management: Manage the specification, selection, and installation of new assembly equipment, automated cells, and specialized fixtures. Oversee vendor management from procurement to final runoff.
• Design for Excellence: Conduct and lead Design for Manufacturability (DFM) and Design for Assembly (DFA) reviews, providing critical feedback to design teams to reduce assembly complexity.
• Validation & Launch: Oversee the installation and commissioning of new lines. Lead validation activities (IQ/OQ/PQ) and ensure processes meet all safety and quality standards before mass production.
• Mentorship: Provide technical guidance and mentorship to entry-level engineers and technicians.