Assembly Testing Engineer

About the role

As an Assembly Testing Engineer at Ford, you will be a key member of the Powertrain Manufacturing Engineering team, driving the development, implementation, and optimization of assembly methods, equipment, and testing strategies for a broad portfolio of powertrain components, including engines, transmissions, axles, and electrified power units.

Key responsibilities

• Develop and maintain Bill of Process (BoP) standards for all assembly sequences, tooling, and testing methods.
• Create assembly process sequences in the Global Study Process Allocation System (GSPAS) and generate functional specifications and 3D models for each workstation.
• Benchmark existing assembly systems across engine, transmission, axle, power unit, rotor/stator, and battery pack lines.
• Design and implement robust testing methodologies for sub‑assemblies such as cylinder heads, pistons, planetary carriers, and battery modules.
• Apply Failure Mode Avoidance tools (PFMEA, Control Plans, SCCAF, EPM) to mitigate risks and eliminate failure modes.
• Develop standard layouts for manual workstations, material handling equipment, and ergonomic safety solutions.
• Utilize Virtual Manufacturing simulations to verify workstation designs and process flows.
• Collaborate with product engineering, manufacturing plants, and suppliers to drive continuous improvement.

Required profile

• Strong background in process engineering and quality assurance within automotive or powertrain manufacturing.
• Experience with virtual manufacturing tools and 3D modeling for workstation design.
• Proven ability to develop and manage detailed process documentation and standards.
• Excellent analytical skills for risk assessment and failure mode analysis.
• Effective collaboration skills across cross‑functional teams and external suppliers.

Required skills

• Virtual Manufacturing simulation
• 3D modeling (CAD)
• PFMEA (Process Failure Mode Effects Analysis)
• Control Plans
• SCCAF (Systematic Component Corrective Action Framework)
• EPM (Engineering Process Management)
• Bill of Process (BoP) development
• Global Study Process Allocation System (GSPAS)