Variation Analysis (Post-Final Design Judgement, FDJ) Engineer

We are the movers of the world and the makers of the future. We get up every day, roll up our sleeves and build a better world -- together. At Ford, we’re all a part of something bigger than ourselves. Are you ready to change the way the world moves?

Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life. We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more!

In this position... 
Ford is expanding our Dimensional Systems capability with a team purpose-built to drive post-Design Freeze execution across vehicle systems during launch and current production. This group owns post-Design Freeze variation analysis encompassing all interior and exterior component and assembly design and tolerance changes, certification of checking fixtures, data-driven management of tolerance concessions and production dimensional issues in partnership with suppliers and plant teams. While you will support pre-Design Freeze activities for purchased assemblies, the primary focus of this role is post-Design Freeze readiness and execution across both purchased and in-house engineered components and assemblies.

As a Dimensional Systems Variation Analysis Engineer, you will develop and apply 3DVSA models to validate component and assembly stack-ups, optimize tooling and fixture strategies, and quantify the impact of tolerance relief and design changes on vehicle fit and function. You will support APQP/PPAP-aligned dimensional deliverables through tool tryout and key build events, disposition deviations based on production data, and drive corrective actions to achieve robust launch capability.

This role is hybrid/onsite as program and launch phases require, with close collaboration at Ford facilities, suppliers, and manufacturing plants. Expect travel of approximately 10–20% within North America, with increased onsite presence during tool tryout, PPAP, and key build events.

What you'll do...

Post Design Freeze

• Review and validate checking fixture designs for interior and exterior components/assemblies to ensure alignment with GD&T requirements.

• Ensure all significant and critical characteristics are captured and measurable in the gauge.

• Participate in digital and physical gauge certification.

• Validate downstream fit and function of proposed component design changes using 3D-VSA.

• Quantify and manage tolerance concessions across build events; assess potential impact on vehicle fit/function and align with APQP/PPAP requirements.

• Analyze internal and supplier production data to identify tolerance improvement opportunities and implement dimensional enablers for non-compliant requirements.

• Provide on-site support at suppliers and Ford plants for dimensional issues during new program launch.

• Lead cross-functional problem-solving (D&R, Manufacturing, Quality, PVT, Suppliers) to determine root cause and implement corrective actions.

Pre Design Freeze

• Develop assembly datum strategies and define drawing GD&T in CATIA/3DX for purchased assemblies (e.g., seat frames, cross-car beams, bumper beams).

• Define and document process flows for purchased assemblies, ensuring consistent datum schemes and feature usage across components, tooling, and assembly operations.

• Perform 3D-VSA studies (Vis-VSA) to predict system capability against appearance and functional requirements.

• Identify and recommend improvements in tooling, processing and fixture strategies.

• Correlate simulation to measurement data and refine models for accuracy.

You'll have...
Bachelor's degree in engineering or equivalent experience.
3+ years of experience in Dimensional Management Engineering/Analysis or equivalent field.

Even better, you may have...
Master's in Engineering.
3+ years performing 3D variation analysis (Vis-VSA, 3DCS, or similar).
Strong knowledge of GD&T (ASME Y14.5) and tolerance stack methods.
Experience with SPC and statistical methods (e.g., Minitab).
Understanding of manufacturing and assembly processes, tooling, fixtures and plant operations. 
Experience with APQP/PPAP, DFMEA/PFMEA and control plans.
Hands-on metrology experience (CMM, laser scanning) and MSA/Gage R&R.
Demonstrated cross-functional collaboration and communication skills (written and verbal).

You may not check every box, or your experience may look a little different from what we've outlined, but if you think you can bring value to Ford Motor Company, we encourage you to apply!

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder…or all of the above? No matter what you choose, we offer a work life that works for you, including:
• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service 
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day 
• Paid time off and the option to purchase additional vacation time. 

This position is a salary grade 5 and ranges from $63,480-106,680.
This position is a salary grade 6 and ranges from $72,480-121,440.
This position is a salary grade 7 and ranges from $84,480-141,360.
This position is a salary grade 8 and ranges from $96,720-162,120.

For more information on salary and benefits, click here: https://fordcareers.co/GSR.

Visa sponsorship is not available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660.

This position is hybrid. Candidates who are in commuting distance to a Ford hub location may be required to be onsite four or more days per week. 

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