Assembly Testing Engineer

As an Assembly Testing Engineer at Ford, you will be a critical expert within the Powertrain Manufacturing Engineering (PTME) team, primarily focused on the development, implementation, and optimization of assembly methods, equipment, and comprehensive testing strategies for a wide range of powertrain components. Your role will span from traditional Engine, Transmission, and Axle assemblies to advanced Power Unit, Rotor/Stator, and Battery Array/Module/Pack assemblies for electrified vehicles. You will be responsible for defining Bill of Process standards for all assembly and testing sequences, ensuring robust, high-quality, and ergonomically sound manufacturing solutions. This position requires a strong blend of process engineering, quality assurance, virtual manufacturing expertise, and a keen focus on developing and deploying effective test methods for various sub-assemblies. You will collaborate extensively with product engineering, manufacturing plants, and suppliers to drive continuous improvement and achieve world-class assembly and testing performance.

Key responsibilities include:
Assembly Process & Standards Development

• Develop and maintain Bill of Process (BoP) standards for all assembly methods and equipment specifications (sequence, clamping, fastening, pressing, testing, etc.).
• Develop assembly process sequences in Global Study Process Allocation System (GSPAS).
• Develop process book/functional specification for each station and identify key tooling components for Bill of Material (BoM), and develop 3D models.
• Deploy standard engineering methods in the development and delivery of assembly processes and systems.
• Benchmark existing assembly systems, including Engine Assembly, Transmission Assembly, Axle Assembly, Power Unit Assembly, Rotor and Stator Manufacturing, and Battery Array, Module & Pack Assembly.

Testing Methodologies & Implementation

• Responsible for all sub-assemblies and test methods, including Cylinder Head Assembly, Piston and Rod Assembly, Planetary Carrier Assembly, off-line assemblies, Main Control Assemblies, etc.
• Develop and maintain robust processes, and mitigate/eliminate all identified failure modes and risks for new programs through Failure Mode Avoidance (e.g., PFMEA, Control Plans, SCCAF, EPM).

Workstation & Equipment Design

• Develop standard layouts for the overall assembly system and manual workstations.
• Deliver manual workstations based on standardized work, including line-side material handling equipment and tooling (tool/bridge rail systems, lift assists, flow racks and fork-free unit load lifts/carts), line-side part placement, and assessment of safety and ergonomic risk factors.
• Determine appropriate material handling requirements (i.e., tool rail systems, lift assists, material racks, etc.).
• Utilize Virtual Manufacturing for simulation verification and workstation development.
• Support the development of 3D station models to easily share with the supply base.

Feasibility & Cost Management

• Provide manufacturing assessments, cost estimates, and feasibility input for future model cost studies.
• Support new model program cost studies and projects.
• Support the Design for Ergonomics procedure for assembly processes to drive Zero Ergonomic issues through engineering.
• Support continuous improvement of Assembly Systems and the introduction of new technologies.
• Assist plants, as required, in resolving significant engineering issues and achieving continuous improvement for both new programs and current production.

Cross-Functional Collaboration

• Support the Quality Operating Systems and Ford Production System (FPS).
• Support simultaneous engineering and feasibility engineering studies among product engineering and production facilities.
• Provide technical expertise to Powertrain Operations (PTO) plants & support strategic priorities.

Education

• Bachelor’s degree in Engineering (Mechanical, Electrical, Manufacturing, or related).

Experience

• Professional experience in manufacturing engineering, with a strong focus on assembly processes, equipment, and testing methodologies.
• Experience with new product introduction (NPI) and the Global Product Development System (GPDS) and familiarity with powertrain assembly (ICE, Transmission, Axle) and/or electrification components (Power Unit, Battery Assembly) is highly preferred.

Technical Knowledge

• Proficiency in developing Bill of Process (BoP) standards for assembly and testing.
• Strong understanding of assembly methods (clamping, fastening, pressing), material handling, and workstation design.
• Experience with Virtual Manufacturing tools for simulation and workstation development.
• Knowledge of Failure Mode Avoidance tools (PFMEA, Control Plans) and ergonomic analysis for assembly processes.
• Familiarity with Global Study Process Allocation System (GSPAS) is a plus.

Language Skills

• Advanced proficiency in English (written and verbal) for global reporting and cross-functional collaboration.

Soft Skills

• Excellent analytical and problem-solving skills to optimize assembly processes and resolve testing issues.
• Strong communication and collaboration skills to work effectively with product engineering, plant teams, and suppliers.
• Detail-oriented with a focus on quality, ergonomics, and continuous improvement.

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