Lead Handles Development Engineer

About the role

Ford is seeking high-caliber Lead Engineers to drive the end-to-end development of exterior and interior door handle systems across multiple current production vehicle programs. This role partners closely with Ford's supplier base to re-engineer handle mechanisms using existing architectures with new suppliers, delivering production-ready solutions on an accelerated timeline. Each Lead Engineer will own a specific handle architecture and its variants, serving as the primary technical point of contact from concept through production launch.

Responsibilities

• Lead supplier partners through an accelerated ("go-fast") design-to-production development process for door handle opening systems
• Own overall technical delivery for assigned handle architectures, including exterior and interior handle mechanisms
• Manage suppliers through all development phases, ensuring parts are released for production tooling
• Ensure all tooled parts are validated and approved per PPAP requirements
• Drive program timing, milestone compliance, and deliverable readiness; proactively identify and resolve risks
• Communicate program status, issues, and recovery plans to Ford management and cross-functional stakeholders
• Collaborate closely with suppliers to develop robust, production-ready designs
• Track development plans and delivery milestones to achieve scheduled PPAP timing
• Perform and lead design, CAD, and drawing reviews
• Coordinate and review analytical verification activities (simulation, calculations, tolerance stack-ups, T&E)
• Ensure designs comply with engineering best practices, Ford standards, and system requirements (Health Charts / Checklists)
• Coordinate technical development activities, schedules, and resolution of engineering issues
• Integrate product, process, and lessons-learned issues into DFMEA documentation
• Coordinate supplier validation testing and review test plans and reports
• Coordinate Ford internal vehicle-level and subsystem validation testing
• Maintain regular communication with internal Ford teams and external suppliers
• Prepare interim and final project reports and technical presentations
• Release components for production (WERS) and support production issues (SREA, Alerts)
• Manage supplier design data within Ford systems (CAD models, drawings, CAE data)

Requirements

• 10+ years of experience in mechanical mechanism development, preferably in latching systems, door handles, or exterior mechanisms
• Strong knowledge of engineering plastics and steels, including manufacturing processes such as injection molding, stamping, and casting
• Experience performing and/or leading tolerance analysis studies
• Proficiency with DFMEA and related quality tools, including:
  • Boundary/Parameter Diagrams
  • Requirements Decomposition Matrix (RDM)
  • Interface Matrices
  • DVP&R, DOE, SPC, statistical analysis
  • Problem-solving methodologies (5D, 8D, 6-Panel, Six Sigma)
• Solid understanding of DFM/DFA and GD&T principles
• Experience reviewing and working in CATIA V5/V6
• Familiarity with Teamcenter / ENOVIA for CAD data management
• Strong written and verbal communication skills
• Proficiency with Microsoft Office (Excel, Word, PowerPoint)

Preferred Qualifications

• Experience with water management and sealing design
• Knowledge of greases and painted plastics
• Familiarity with embedded electronics such as microswitches and small wiring harnesses
• Experience with tolerance analysis tools such as C-Tol, 3DCS, Enventive, or VSA
• Experience with CAE tools such as ADAMS, Working Model, CATIA FEA, HyperMesh, or similar