Stator Welding Process Engineer

Job description

Results-oriented Manufacturing Engineering professional with comprehensive experience in leading and optimizing new program development and launch cycles for welding stator assemblies welding and electric vehicle powertrains, from initial concept through production.

Expert in developing, maintaining, and continuously improving stator assembly processes welding (including winding, insulation, and integration), manufacturing standards, and quality operating systems, utilizing robust failure mode avoidance methodologies such as Process Failure Mode and Effects Analysis (PFMEA), Control Plans, and Error Proofing, critical for achieving high-quality stator production.

Proven ability to provide critical technical expertise and strategic support to electric motor manufacturing facilities, Product Engineering, and suppliers, driving stator manufacturing feasibility, cost efficiency, new assembly technology implementation, and continuous improvement initiatives.

Adept at conducting feasibility studies for stator designs, managing supplier technical evaluations for components and equipment, and ensuring compliance with corporate objectives and regulatory requirements.

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.

+ · Lead PTME Engineering Studies, including What-if scenarios and Vignettes through Program Approval (PA) responses (prior to Long Lead Funding and Formal RFQs) for new electrification programs, specifically focusing on welding process for stator assembly within Power Unit, and eDrive systems.
+ · Develop comprehensive manufacturing study responses and management review decks (e.g., Deep Dive Decks) pertaining to stator assembly.
+ · Complete study work in collaboration with Product Development (PD), incorporating product assumptions and Bill of Design (BoD) / Bill of Process (BoP) requirements specific to stator welding process.
+ · Support the Digital Pre-Assembly Assessment (DPA5) process through the development of welding process component Manufacturing Design Specification (MDS) and Manufacturing Process Specification (MPS) Key Process Attribute Controls (KPACs).

Complete Manufacturing Assessment (MA) assessments, identifying any BoD/BoP updates needed for legacy equipment used in stator assembly.
+ · Support simultaneous engineering and feasibility engineering studies among product engineering, manufacturing engineering, and supplier organizations for stator welding processes.
+ · Fully complete the MA0 and MA1 assessments for stator assembly programs.
+ · Review and incorporate any High Hurt Actions related to stator assembly manufacturing.

Develop the manufacturing study response and management review decks (e.g., Deep Dive Decks) for stator assembly initiatives.
+ · Completed study and generation of Global Program Metric Reports (GPRM) for stator assembly programs.

Development of version 0 (and study of alternatives) for stator welding processes.
+ · Support and concur on Hours Per Unit (HPU) target setting for stator assembly.
+ · Co-Lead resolution of manufacturing concerns and feasibility issues related to welding process within the Component Program Module Team (CPMT).
+ · Deliver Digital Pre-Assembly Assessment (DPA5) reviews and assess Bill of Process (BoP)/Bill of Design (BoD), Manufacturing Design Specification (MDS)/Manufacturing Process Specification (MPS) for assigned stator assembly component/process in Engineering Reviews.
+ · Responsible for procurement, design, runoff, delivery, and launch of new/re-tooled equipment to support new programs for welding process.
+ · Understand and follow Powertrain Manufacturing Engineering (PTME) Strategies, Procedures, Guidelines, Bill of Process, and MDS/MPS requirements for stator assembly, documenting gap approval with deviation acceptance.
+ · Implement standardized engineered solutions for stator welding, with lead responsibility for ergonomics, safety, productivity, and process conformity.

Deploy standard engineering methods in the development and delivery of stator assembly processes and systems.
+ · Incorporate continuous improvements utilizing ME Continuous Improvement / Lessons Learned, Deviation, and Decision Record Processes for stator assembly.

Develop and deliver Engineering Statement of Work (ESWP), enquiry specification/bid packages, Statement of Work (SPA), recaps, and issue Purchase Requisitions for welding process-related equipment.
+ · Drive Investment Efficiency process with Product Development (PD) and Original Equipment Manufacturers (OEMs) for stator assembly 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 assembly.
+ · Champion review and approval of OEM safety risk assessments with Controls, Welding and Safety for stator assembly equipment.
+ · Provide cost estimates and achieve Facilities & Tooling (F&T) / Hours Per Unit (HPU) objectives for Welding process and stator assembly.
+ · Assume overall financial responsibility for respective stator assembly 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 welding projects.
+ · Attend/support all welding process layout reviews.
+ · Participate in Peer Reviews – share and cascade Lessons Learned specific to stator assembly.
+ · Deliver Virtual Assembly or Manufacturing Builds for stator welding process.
+ · Complete MA assessment input and support (including deviation process and open issue resolution) for welding process.
+ · Manage Bill of Develop of Make Like Production (MLP) plan with Prototype Operations for stator assembly builds.
+ · Communicate changes post Build Purchase Order to suppliers and assess feasibility for welding and stator assembly components.
+ · Assess all Product Development (PD) changes from Program Start Concept (uPSC) to Job 1 (uJ1) for feasibility trades related to welding process and coordinate with groups responsible for maintenance planning and spare requisitioning.
+ · 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 welding equipment.
+ · Develop process documentation (e.g., Control Plan, PFMEA, Global Standardized Process Adherence Sheet (GSPAS), Process Sheets, Process Illustrations, tooling, and gauging documentation, etc.) for stator assembly.
+ · Coordinate PROTAG sign-off for stator assembly 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.
+ · Support technology development and innovation Process Deviation Requests / Decision Records.
+ · Interface with plant teams such as the launch team, New Model Launch (NML), and skilled trades for stator assembly installation equipment, maintenance planning, and spare parts requisitioning.

+ · Engineering Level Finished, (Mechanical, Electromechanical or kindred).
+ · Experience in welding systems
+ · Basic knowledge of laser systems
+ · 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.

**Requisition ID** : 51174

Required Skill Profession

Other General