In this role, the E-Motor Powertrain Rotor Manufacturing Engineer will work with Product Development and Suppliers, to successfully develop and launch next-generation E-Motor Powertrain rotor systems and all associated aluminum casting processes. Successful candidates will have a proven record of working with cross functional teams in the development and implementation of high-volume manufacturing systems as well as complex castings.

The E-Motor Powertrain Rotor Manufacturing Engineer will be required to apply their knowledge to high volume manufacturing systems and various casting alloys and processes, including but not limited to gravity, low-pressure, and high pressure die casting. In this role, the rotor engineer will have direct impact over the design and processing of E-Motor Powertrain rotors and casting processes in future Ford products. 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.

Minimum Requirements

Bachelor of Science/Engineering; MBA/MS preferred - Chemical/Electrical/Mechanical or Metallurgy/Materials Science. 5+ years prior experience with high pressure die casting, or vertical cold chamber die casting. 5+ years prior experience in a high-volume manufacturing environment. Strong communication skills, both written and oral; ability to present, persuade, and collaborate at all levels of the organization. Working level knowledge of casting, post processing, and die development processes. Knowledge of the secondary operations associated with castings, including, but not limited to trimming, fettling, deburring, and quality checks. Knowledge of aluminum alloys used for castings. Experience performing casting manufacturing feasibility assessments. Foundry operational experience in casting manufacturing processes and process control. 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. Highly motivated self-starter capable of driving change and influencing engineering decisions, with or without authority. Proven track record of specifying, procuring, and installation of high-volume manufacturing equipment, inclusive of die casting processing.

Preferred Qualifications

Casting Aluminum into Steel Rotor core laminations, or casting aluminum with imbedded steel parts. Experience introducing & establishing a new Core Competency into production in a Ford plant. Casting Porosity inspection techniques such as X-Ray inspection. Proven track record of delivering major product launches in an automotive manufacturing facility. Familiarity with required Safety and Facilities requirements to install Die Casting equipment in a Ford facility. 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. Ability to travel both domestically and internationally; travel may be required from 20% - up to 80% of time. Support simultaneous engineering and feasibility engineering studies among product engineering, manufacturing engineering and supplier organizations. Support supplier selection evaluation process through manufacturing assessments and assist Purchasing in the evaluation, development, and selection of suppliers and subcontractors. Provide  support for rotor casting prototype planning, process development and scheduling. Support on-time quality prototype delivery of new Ford components at internal and external supplier facilities. Evaluate innovative and disruptive emerging processes and material technologies for potential application to Ford products. Support Product Engineering in the selection and specification of component materials and test procedures. Support Purchasing with the issuance of prototype and production tooling orders, following the Ford Tooling Procurement Management Process, as required. Assist Ford manufacturing plants, as required, in resolving significant engineering issues and achieving continuous improvement for both new programs and current production. Provide technical support, as required, to Purchasing (Component Buyers and Supplier Technical Assistance) involving the resolution of casting related productivity and quality issues and the development of external casting suppliers.