Process Engineer, Ford Energy
Ford Energy · Glendale Junction, KY · 3 wk ago
On-siteManagement$65k–$109k/yrFull-time
Job Summary
At Ford Energy, you have the backing of an industrial manufacturing powerhouse with the agility of a dedicated energy startup offering industry leading technology. We offer a competitive compensation package including performance-based bonuses, Ford vehicle discounts, and the opportunity to shape the energy strategy of one of the world's most iconic brands.
What you'll do
- Greenfield Production Excellence & Manufacturing Systems
- Lead the design and implementation of the Ford Energy Production System (FEPS), with a focus on standardized work, line balancing, and optimized workstation layouts.
- Develop labor standards and manpower plans for cell, module, and pack assembly to maximize utilization and efficiency.
- Drive continuous improvement in safety, quality, and productivity across all production lines.
- Analyze production constraints and perform equipment cycle time studies to optimize throughput, Jobs Per Hour (JPH), and First Time Through (FTT) quality.
- Design and refine station layouts using CAD, incorporating tooling, material presentation, and error-proofing (Poka-Yoke) for zero-defect manufacturing.
- Conduct ergonomic job evaluations and implement workstation designs that meet high safety standards in automated, high-speed production environments.
- Manage procurement, commissioning, capability validation, and debugging of new production equipment, including vendor site buy-offs.
- Collaborate with Product Design, suppliers, and manufacturing teams to develop optimal process strategies, including gauging, torque strategies, and in-process testing.
- Leadership & Culture
- Embrace the Gemba philosophy: Regularly engage on the production floor to identify bottlenecks, verify standardized work adherence, and solve problems in real time.
- Develop "Leaders as Teachers": Mentor Production and Operations teams on lean principles, including takt time vs. cycle time and waste elimination.
- Remove Barriers: Proactively mitigate risks in the launch phase to ensure seamless equipment buy-offs and successful Start-Of-Production(SOP).
- Proactive Problem-Solver: Catalyst who identifies gaps and proposes solutions before they become issues.
- Champion Transparency: Partner cross-functionally with Manufacturing Engineering, Quality, and Operations to achieve Ford Energy’s Vision, Mission, and Values.
- Strategic Management & Integrity
- Establish and track Production Key Performance Indicators (KPIs), including OEE (Overall Equipment Effectiveness), scrap rates, and FTT quality.
- Lead cross-functional initiatives in quality to achieve "No Faults Forward" and zero defects on the production line.
- Coordinate quality containment actions, dock holds, and special checks to eliminate any impact on the customer, maintaining detailed traceability records.
- Lead 8D root-cause resolution for warranty and battery operations concerns in collaboration with Quality, MP&L, and Assembly teams.
- Manage and direct statistical process control (SPC) activities, execute measurement systems analysis (MSA), and variable data analysis to drive process capability (Control Plans).
- Review rejected parts for quality integrity, determine corrective actions, and issue daily quality reports.
- Manage the Engineering Change Management (ECM) process for the production floor, ensuring all process modifications are documented, and process sheets/instructions are updated accurately.
Requirements
- Education: Bachelor’s degree in Engineering (e.g., Mechanical, Electrical, Chemical, Industrial, Manufacturing, or a related engineering field)
- Experience: 3-5+ years of progressive experience in Industrial Engineering or Manufacturing Engineering within a high-volume production environment. Even better, you may have...
- Experience in Greenfield site development or high-volume automotive, battery, or electronics manufacturing.
- Leverage of Lean Manufacturing and/or Six Sigma certification (Green Belt or Black Belt).
- Experience with 8D, 5-Why analysis, DMAIC/DMADV methodologies, and lean tools (5S, Kanban, Poka-Yoke, Value Stream Mapping).
- Familiarity with engineering change and release systems (e.g., WERS, CORA, or similar).
- Strong communication, collaboration, and team-building skills.
- Passion for energy systems and U.S. energy independence.
- Advanced proficiency in AutoCAD, MODAPTS, and manufacturing simulation tools.
- Leadership Attributes: Strategic visionary, decisive under pressure, adaptable.
Technical Knowledge
- Advanced proficiency in AutoCAD, MODAPTS, and manufacturing simulation tools.