PTME Casting Engineer

As a Casting Engineer at Ford, you will be a critical technical expert within the Powertrain Manufacturing Engineering (PTME) team, specializing in the design, development, and implementation of manufacturing processes for powertrain castings. Your primary focus will be to ensure the manufacturing feasibility of casting designs from initial concept through to production launch, supporting both traditional and electrified powertrain components. You will lead the New Model Launch Component Committee (NMLCC) process for castings, ensuring cross-functional alignment to create robust, manufacturable designs that meet Ford's stringent quality and performance standards.

This role requires a deep understanding of casting processes, materials, and tooling, along with strong collaboration skills to work effectively with Product Engineering, Machining teams, and external suppliers. You will play a key role in evaluating emerging casting technologies, optimizing designs for manufacturing, and resolving complex engineering issues to support Ford's global new program launches and continuous improvement initiatives.

Your role will encompass program leadership, technical process development, and financial stewardship. Key responsibilities include:

• Manufacturing Feasibility & Design for Manufacturing (DFM): 
  • Lead the New Model Launch Component Committee (NMLCC) process to establish frameworks for cross-functional teams to develop and implement manufacturing-feasible casting designs and processes. Document this process using the NMLCC Process Development Log.
  • Coordinate casting and forging design between Product Engineering, PTME - Machining, and external casting suppliers to ensure 'design for manufacturing feasibility' for new Powertrain castings.
  • Support Product Engineering in the selection and specification of component materials and test procedures.
• Program Assessment & Reporting: 
  • Fully complete the MA0 – MA3 assessments for casting-related programs.
  • Report out on the status of the NMLCC process through the Delivery Team (integrator in GPDS, etc.).
  • Deliver technical content to new programs to ensure program objectives are met.
• Supplier & Prototype Management: 
  • Support the supplier selection evaluation process through manufacturing assessments and assist Purchasing in the evaluation, development, and selection of casting suppliers and subcontractors.
  • Provide support for casting prototype planning, process development, and scheduling.
  • Support on-time quality prototype delivery of new Ford components at internal and external supplier facilities.
  • Support Purchasing with the issuance of prototype and production tooling orders, following the Ford Tooling Procurement Management Process, as required.
  • Provide technical support, as required, to Purchasing (Component Buyers and Supplier Technical Assistance) involving the resolution of casting-related productivity and quality issues and the development of external casting suppliers.
• Process Development & Improvement: 
  • Develop, maintain, and continuously improve Powertrain Standards, Strategies, Bill of Process (BOP), Procedures, and Guidelines as part of the Powertrain Manufacturing Engineering Quality Operating Systems (PTME QOS).
  • 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).
  • Lead Continuous Improvement and Lessons Learned Processes specific to casting manufacturing.
  • Evaluate innovative and disruptive emerging processes and material technologies for potential application to Ford products.
• Plant & Technical Support: 
  • Assist Ford manufacturing plants, as required, in resolving significant engineering issues and achieving continuous improvement for both new programs and current production related to castings.
  • Provide technical expertise to Powertrain Operations (PTO) plants & support strategic priorities.
  • Provide support for Purchasing, PTO Product Engineering, and Suppliers in relation to emerging markets.

• Education: Bachelor’s degree in Engineering (Materials Science, Metallurgical, Mechanical, Manufacturing, or related field). 

• Experience:

  • Professional experience in casting manufacturing processes (e.g., sand casting, die casting, permanent mold, forging). 

  • Experience with new product introduction (NPI) and the Global Product Development System (GPDS), specifically related to component design and manufacturing feasibility. 

  • Familiarity with powertrain components (ICE, Transmission, Axle, Electrification) is highly preferred. 

• Technical Knowledge:

  • Strong understanding of casting design principles, material properties, and process limitations. 

  • Proficiency in Failure Mode Avoidance tools (PFMEA, Control Plans) and Design for Manufacturing (DFM) methodologies. 

  • Experience with MA0-MA3 assessments and the NMLCC process. 

  • Knowledge of tooling procurement and supplier technical evaluation

• .Project Management: Proven ability to manage program budgets, timing plans, and technical supplier evaluations. 

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

• Soft Skills: 

  • Excellent communication and interpersonal skills for effective collaboration with Product Engineering, Machining teams, and external suppliers.

  • Strong analytical and problem-solving abilities to resolve complex casting-related issues.

  • Ability to lead cross-functional teams and drive consensus on technical solutions.