Unicasting Process Mfg Engineer (HPDC)

In this role, the Unicasting Casting Process Engineer will define and deliver next-generation Unicasting manufacturing processes in support of future-model vehicle programs. Successful candidates will have a proven record of working with cross functional teams in the development and implementation of processes for structural aluminum high pressure die castings.

The Unicasting Casting Process Engineer will be responsible for defining and implementing the casting process, from early program planning through facility launch. In this role, the engineer will have direct-line impact over the process development, bill of process and equipment identification and integration of Unicastings. This process is a new to Ford manufacturing process and must combine both technical and leadership capabilities to drive success. Ideal candidates must navigate and drive change in a complex internal environment, challenging the status quo as we define an all-new way of manufacturing vehicles.

What you'll do:

• Work within a cross-functional manufacturing team towards development and execution of Unicasting manufacturing from early concept through facility launch.
• Advanced knowledge of casting manufacturing processes with hands-on experience.
• Leverage expertise from internal and external workgroups to drive strategy, resolve challenges, and deliver results.
• Utilize knowledge of quality processes and systems to meet stringent industry and customer requirements.
• Drive “Voice of Manufacturing” throughout product development lifecycle to ensure robust, feasible, and manufacturable casting assembly designs.
• Define and launch formal equipment and process standards for high pressure die cast tooling, casting equipment and post-processing cells.
• Lead scope-of-work development and competitive bidding exercises for Unicasting manufacturing systems.
• Drive continuous benchmarking of best-in-world practices for HPDC applications and utilize findings to improve Ford strategy.
• Work within a manufacturing engineering team to execute tooling design reviews, risk mitigation, commissioning processes, and launch handoff with a Ford manufacturing facility.
• Deliver on-time and on-budget launch for upcoming Unicasting programs.

Minimum Qualifications:

• Bachelor of Science, Mechanical Engineering
• 5+ years prior experience with high pressure die casting, preferably for structural applications.
• Working level knowledge of casting, post processing, and die development processes.
• Working level knowledge of core making processes and materials.
• Knowledge of the secondary operations associated with castings, including, but not limited to trimming, fettling, deburring, and quality checks.
• Knowledge of both iron and aluminum alloys used for castings.
• Travel may be required from 25% - up to 80% of time.
  • The lower end means working from home base (Dearborn) with minimum travel to Supplier/Vendors, Test facilities or out of state (of Michigan) Plants/Suppliers.
    The higher end of travel means supporting implementation/launch teams on site at the out of state (of Michigan) Plants/Suppliers.  This could require traveling from ~3 months up to ~ 1 ½ years working on-site at a Plant. Per HR guidelines, when supporting out of state you are allowed to travel home every other weekend.

Preferred Qualifications:

• Ability to work in a production setting and aid in troubleshooting of supplier equipment and processes. Possess practical problem-solving skill and the ability to address a variety of variables in situations where only limited standardization exists.
• Understanding of MagmaSoft or other casting simulation software results.
• Excellent problem-solving skills and the ability to make decisions in a fast paced, dynamic environment.
• Exceptional communication and interpersonal skills to present, persuade, and collaborate at all levels of the organization.
• Highly motivated self-starter capable of driving change and influencing engineering decisions, with or without authority.
• Experience performing casting manufacturing feasibility assessments.
• Foundry operational experience in casting manufacturing processes and process control.

 

You may not check every box, or your experience may look a little different from what we've outlined, but if you think you can bring value to Ford Motor Company, we encourage you to apply!

 

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new