Casting Manufacturing Engineer

Ford - Dearborn, MI

Full-time - Mid Level

Remote - Dearborn, MI

Transportation Equipment Manufacturing

About the position

The Casting Manufacturing Engineer at Ford Motor Company will collaborate with Product Development and suppliers to develop and launch next-generation castings, focusing on high pressure die casting processes. This role requires a strong background in various casting alloys and processes, and the ability to drive change in a complex environment while ensuring manufacturing feasibility for new Ford products.

Responsibilities

• Drive the New Model Launch of Complex Casting (NMLCC) process to create Program/Component specific plans for manufacturing feasible casting designs.
• Document the NMLCC process using the NMLCC Process Development Log.
• Report on the status of the NMLCC process through Delivery Team.
• Provide technical support to Product Development Component Program Module Teams and coordinate casting design with Product Engineering and external suppliers.
• Support new model program cost studies and projects.
• Support the Digital Preassembly 5 process through the development of Manufacturing Design Specifications and Manufacturing Process Specifications.
• Complete Manufacturing Assessments.
• Support simultaneous engineering and feasibility engineering studies among product engineering, manufacturing engineering, and supplier organizations.
• Assist in supplier selection evaluation through manufacturing assessments and support Purchasing in supplier development.
• Provide support for casting prototype planning, process development, and scheduling.
• Ensure on-time quality prototype delivery of new Ford components at internal and external supplier facilities.
• Evaluate innovative and disruptive emerging processes and material technologies for potential application to Ford products.
• Support Product Engineering in selecting and specifying component materials and test procedures.
• Assist Purchasing with prototype and production tooling orders as required.
• Help Ford manufacturing plants resolve significant engineering issues and achieve continuous improvement.

Requirements

• Bachelor of Science/Engineering in Chemical, Electrical, Mechanical, Metallurgy, or Materials Science.
• 5+ years of experience with high pressure die casting, preferably for structural applications.
• Strong communication skills, both written and oral.
• Working knowledge of casting, post processing, and die development processes.
• Knowledge of core making processes and materials.
• Understanding of secondary operations associated with castings, including trimming, fettling, deburring, and quality checks.
• Knowledge of iron and aluminum alloys used for castings.
• Understanding of casting simulation software results, such as MagmaSoft.
• Excellent problem-solving skills and decision-making ability in a fast-paced environment.
• Exceptional communication and interpersonal skills to collaborate at all levels of the organization.
• Highly motivated self-starter capable of driving change and influencing engineering decisions.
• Experience performing casting manufacturing feasibility assessments.
• Foundry operational experience in casting manufacturing processes and process control.

Nice-to-haves

• Proven track record of delivering major product launches in an automotive manufacturing facility.
• Ability to work in a production setting and troubleshoot supplier equipment and processes.
• Ability to travel both domestically and internationally.

Benefits

• Immediate medical, dental, and prescription drug coverage
• Flexible family care and parental leave
• Vehicle discount program for employees and family members
• Tuition assistance
• Established and active employee resource groups
• Paid time off for community service
• Generous paid holidays, including the week between Christmas and New Year's Day
• Paid time off with the option to purchase additional vacation time.