Job Description
Results-oriented Engineering professional with comprehensive experience in leading and optimizing new program development and launch cycles for stator assembly testing and validation, from initial concept through production.
Expert in developing, maintaining, and continuously improving stator test plans, procedures, and quality operating systems, utilizing robust failure mode avoidance methodologies such as PFMEA, Control Plans, and Error Proofing, critical for achieving high-quality stator performance and reliability.
Proven ability to provide critical technical expertise and strategic support to electric motor manufacturing facilities, Product Engineering, and suppliers, driving stator test feasibility, test equipment efficiency, new testing technology implementation, and continuous improvement initiatives.
Adept at conducting validation studies for stator designs, managing supplier technical evaluations for test equipment, and ensuring compliance with corporate objectives and regulatory requirements.
Responsibilities
- Lead PTME Led Engineering Studies, including What-if scenarios and Vignettes through Program Approval (PAPA) responses (prior to Long Lead Funding and Formal RFQs) for new electrification programs, specifically focusing on stator testing and validation within Power Unit, and eDrive systems.
- Develop comprehensive stator testing study responses and management review decks (e.g., Deep Dive Decks).
- Complete stator testing study work in collaboration with Product Development (PD), incorporating product assumptions and Bill of Design (BoD) / Bill of Process (BoP) requirements specific to stator testability and performance verification.
- Support the Digital Pre-Assembly Assessment (DPA5) process through the development of stator testing component Measurement Data Specification (MDS) and Measurement Process Specification (MPS) Key Process Attribute Controls (KPACs).
Complete Testability Assessment (TA) assessments, identifying any BoD/BoP updates needed for legacy test equipment used in stator validation.
- Support simultaneous engineering and feasibility engineering studies among product engineering, manufacturing engineering, and supplier organizations for stator testing processes.
- Fully complete the TA0 and TA1 assessments for stator testing programs.
- Review and incorporate any High Hurt Actions related to stator testing and quality.
- Develop the stator testing study response and management review decks (e.g., Deep Dive Decks).
- Complete stator testing study and Global Program Reporting Metric (GPRM) input.
- Develop test lab/line layout release (and study alternatives) for stator testing.
- Support and concur on test throughput and coverage target setting for stator testing.
- Co-Lead resolution of stator testing concerns and validation issues within the Component Program Module Team (CPMT).
- Deliver Digital Pre-Assembly Assessment (DPA5) reviews and assess Bill of Process (BoP)/Bill of Design (BoD), Measurement Data Specification (MDS)/Measurement Process Specification (MPS) for assigned stator testing component/process in Engineering Reviews.
- Responsible for procurement, design, runoff, delivery, and launch of new/re-tooled stator test equipment to support New Programs.
- Understand and follow Powertrain Manufacturing Engineering (PTME) Strategies, Procedures, Guidelines, Bill of Process, and MDS/MPS requirements for stator testing, documenting gap approval with deviation acceptance.
- Implement standardized engineered solutions for stator test equipment with lead responsibility for ergonomics, safety, data integrity, and test result conformity.
- Deploy standard engineering methods in the development and delivery of stator testing processes and systems.
- Incorporate continuous improvements utilizing ME Continuous Improvement / Lessons Learned, Deviation, and Decision Record Processes for stator testing.
- Develop and deliver Engineering Statement of Work (ESWP), enquiry specification/bid packages, Statement of Work (SPA), recaps, and issue Purchase Requisitions for stator testing related equipment.
- Drive Investment Efficiency process with Product Development (PD) and Original Equipment Manufacturers (OEMs) for stator testing projects.
- Follow quality processes (Reconciliation Matrix/Control Plan, Special Characteristics Communication and Agreement Forms (SCCAF), Process Failure Mode & Effect Analysis (PFMEA), Error Proofing) for stator testing.
- Champion review and approval of OEM safety risk assessments with Controls and Safety for stator test equipment.
- Provide cost estimates and achieve Facilities & Tooling (F&T) / Test Coverage objectives for stator testing.
- Assume overall financial responsibility for respective stator testing program content; update and track Purchase Order (PO) authorizations and future commitments in the program checkbook.
- Responsible for overall timing plans and recovery actions for stator testing projects.
- Attend/support all test lab/line layout reviews.
- Participate in Peer Reviews – share and cascade Lessons Learned specific to stator testing.
- Deliver Virtual Test Rig or Test Sequence Builds.
- Complete Testability Assessment (TA) input and support (including deviation process and open issue resolution) for stator testing.
- Manage Bill of Develop of Make Like Production (MLP) plan with Prototype Operations for stator testing validation.
- Communicate changes post Build Purchase Order to suppliers and assess feasibility for stator testing components.
- Assess all Product Development (PD) changes from Program Start Concept (uPSC) to Job 1 (uJ1) for test feasibility trades related to stator performance and coordinate with groups responsible for maintenance planning and spare requisitioning for test equipment.
- Request and ensure on-time delivery of all Original Equipment Manufacturer (OEM) documentation (e.g., Reliability and Maintainability (R&M), Spare Parts lists, Manuals, final Installation Drawing packages, PM Plans, Energy Control Lockout (ECPL) Placards etc.) for stator test equipment.
- Develop process documentation (e.g., Control Plan, PFMEA, Global Standardized Process Adherence Sheet (GSPAS), Test Specifications, Test Procedures, Test Data Analysis documentation, tooling, and gauging documentation, etc.) for stator testing.
- Coordinate PROTAG sign-off for stator testing processes.
- Complete Machine Identification and Acceptance System (MIDAS) and ensure all required uploads are present (e.g., Equipment Validation Plan (EVP), Capability, etc.) prior to sign-off and issue resolution for stator test equipment.
- Support technology development and innovation Process Deviation Requests / Decision Records for stator testing.
- Interface with plant teams such as the launch team, New Model Launch (NML), and skilled trades for stator test equipment installation, maintenance planning, and spare parts requisitioning.
Qualifications
- Engineering Level Finished, (Mechanical, Electromechanical or kindred).
- High proficiency in English.
- Soft skills
- Leadership skills
- Problem solving tools (8D and 5W's).
- Skills in AutoCAD, Quality Tools (Process Capabilities), Microsoft Office, especially Excel, Basic Statistical skills and drawing interpretation.
Acknowledge of PFMEA & DFMEA Disciplines.
TQM Management and Kaizen Methods.
Acknowledge in 6 Sigma Disciplines.
About Us
At Ford Motor Company, we believe freedom of movement drives human progress.
With our incredible plans for the future of mobility, we have a wide variety of opportunities for you to accelerate your career and help us define tomorrow’s transportation.
About The Team
We build world-class vehicles in our plants around the world, constantly developing new technologies and processes to further increase our efficiency.
It’s our people who really make the difference.
We encourage all of our employees to think outside the box to help us find better and more efficient ways to manufacture our vehicles.
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