Provide specialist engineering services for UP/UN Body Functional Trims and Heat Shields covering design, development, supplier industrialization, validation, PPAP, and launch support through MP-2 and J1+90.
Core Responsibilities:
- Milestone and Governance
- Own FEDE deliverables, gateway readiness, and timing adherence; maintain full DVP traceability and status.
- Align DVPs with Core Technical Specialists; keep FEDE up to date with proof of completion.
- Supplier and Change Management
- Partner with suppliers to forecast milestones, confirm part supportability, and track tool readiness.
- Lead Concern Release: author changes with detailed scope, timing, and cost; drive approvals and disciplined implementation.
- Coordinate with interfacing DR owners to manage impacts and maintain package/attribute integrity.
- Engineering and Validation Execution
- Define and execute DV (CAE and physical) and PV plans; commission proto builds/tests when indicated by CAE.
- Close DV/PV issues with appropriate design/process fixes; verify via re-test/correlation as needed.
- Maintain and update DFMEA, P-Diagram, and SCCAF based on latest learnings.
- Industrialization, PPAP, and Launch
- Lead PPAP through PSW; plan and execute line trials and build events with plants.
- Resolve design, supplier quality, and manufacturing issues during change implementation up to J1+90.
- Ensure Launch builds adhere to Global LQOS standards and roles responsibilities.
- Reporting and Ways of Working
- Produce rigorous validation and issue investigation reports (including 8D) to IMG PD standards with complete backup data.
- Maintain a collaborative, hands-on presence with daily engagement across CFTs, suppliers, and plants.
- Success Measures (KPIs)
- Robust, risk-managed program plan; lessons learned applied from prior launches.
- On-time FEDE/gateway deliverables; zero meeting delays; timely signoffs.
- CAD proposals delivered to meet design-phase milestones.
- Zero in-plant defects that should have been caught at supplier signoff.
- Pre-production build issues: root cause and ICA within 24 hours.
- Clean launch and field performance with proactive risk mitigation.
Skill set:
- CAD/PLM: 3DX/CATIA V6/V5; Teamcenter, Vis Mockup, DMU. Program control: GPDS; FEDE milestones; DVP; Concern Release; 50:50 DR/CAD. Validation: DV/PV plans; CAE-to-proto; rapid 8D RCA; ICA/PCA closure. Manufacturing/launch: DFM/tooling; PPAP/PSW; line trials; plant support to J1+90. Suppliers/CFTs: Drive suppliers; align DR / CAE / STA / VOME / Attributes; LQOS; DFMEA, P Diagram, SCCAF; proactive risk/Plan B.
Domain Knowledge:
- Systems and Components
- UP/UN Body Functional Trims and Heat Shields: package constraints, interfaces, mounting strategies, durability, NVH, and thermal protection near exhaust/powertrain and underbody zones.
- Materials and construction methods for heat shields (aluminized steel, stainless, multi-layer insulation, embossed/beaded forms) and functional trims (stamped metal, molded plastics, clips/fasteners, adhesives/tapes).
- Manufacturing and Tooling
- Stamping/forming/embossing, piercing, clinching/riveting, spot welding, adhesive bonding, and tape applications; design for assembly and service access.
- Tooling feasibility, draw/bead strategies, flange and hole pattern optimization, tolerance stack-ups, and GDT appropriate for body-in-white and underbody environments.
- Validation Methods
- CAE: thermal mapping, conduction/convection/radiation assessments, modal/vibration for rattle robustness, durability.
- Physical testing: thermal soak, hot-spot verification, rattle/buzz, corrosion/stone-chipping exposure, vibration/durability, fit-and-finish checks.
- DVPR planning, correlation strategies, acceptance criteria, and re-test closure protocols.
- Quality, Launch, and Compliance
- APQP/PPAP/PSW, control plans, process capability considerations, and run-at-rate expectations.
- Ford processes and standards: GPDS, FEDE, LQOS, DFMEA, P-Diagram, SCCAF, Concern Release, and AIMS.
- Build phases and events: DCV builds, pre-production/line trials, MP-2, and support through J1+90.
- Attribute alignment: thermal, NVH, durability, corrosion, and serviceability requirements at vehicle level.
- Cross-Functional Ecosystem
- Collaboration with DR, CAE, STA, VOME, Attribute Teams, and Global/Regional engineering; effective supplier development and escalation paths for timing, quality, and cost Purpose.
