Power Electronics Gauge Engineer

As a Powertrain Manufacturing Engineer at Ford, you will play a pivotal role in the Global Product Development System (GPDS), serving as the bridge between product design and physical production. You will be responsible for leading the planning, development, and implementation of manufacturing processes, equipment, and facilities for a wide range of powertrain programs. Your scope will include traditional Internal Combustion Engine (ICE), Transmission, and Axle programs, as well as high-priority Electrification projects such as Power Units, eDrives, and Battery systems.

The ideal candidate is a technical leader who can navigate complex engineering studies from early concept (uPSC) through to final launch (uFSR). You will ensure that all manufacturing solutions align with Ford’s Global Bill of Process (BOP), quality standards, and investment efficiency goals. By collaborating with Product Engineering, Plant Operations, and external suppliers, you will drive continuous improvement and ensure our facilities are equipped to deliver world-class quality and performance.

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

· Program Leadership & Planning: Lead power electronics manufacturing and inspection activities within global powertrain programs (M4–M6) throughout the GPDS cycle. Conduct manufacturing feasibility studies, develop “what-if” scenarios, and participate in deep-dive management reviews to ensure robust inspection strategies for electrification components.

· Inspection & Quality Validation Ownership: Define and implement the inspection strategy for critical manufacturing processes including laser welding, selective soldering, and vacuum soldering. Own the validation and capability of inline inspection systems such as AOI and AXI, ensuring proper defect detection, measurement accuracy, and compliance with quality standards.

· Laboratory Testing & Failure Analysis: Lead laboratory-based validation activities including cross-section analysis for solder joints and laser welds. Establish testing methodologies, conduct root cause analysis, and ensure correlation between inline inspection systems and laboratory validation results.

· Process & Quality Engineering: Develop and maintain robust quality assurance methods using Failure Mode Avoidance tools. Deliver key quality documentation including PFMEA, Control Plans, SCCAF, and Error Proofing Matrices (EPM) to support reliable manufacturing processes.

· Technical Implementation & Equipment Validation: Support the design, procurement, runoff, and validation of inspection and laboratory equipment. Ensure all systems meet safety, ergonomic, productivity, and quality capability requirements, while coordinating equipment reviews and digital validation processes.

· Financial & Investment Management: Support investment efficiency by identifying opportunities for inspection equipment reuse or optimization. Track equipment-related purchases and support program budget monitoring to ensure alignment with HPU and F&T objectives.

· Cross-Functional Collaboration: Work closely with Product Engineering, Manufacturing, Quality, and OEM suppliers to ensure manufacturing feasibility and effective inspection coverage. Support Component Program Module Teams (CPMT) and plant teams during equipment installation, validation, and launch to ensure a smooth transition into production.

· Technical Leadership in Vision & Inspection Systems: Act as the technical reference for AOI, AXI, and laboratory inspection technologies, driving continuous improvement in defect detection, inspection coverage, and manufacturing quality performance.

· Supplier Management: Lead the technical evaluation and selection of suppliers. You will ensure on-time delivery of OEM documentation (manuals, PM plans, spare parts lists) and conduct benchmarking studies to support manufacturing decisions.

· Continuous Improvement: Champion the Lessons Learned process and implement standardized engineered solutions. You will document results from engineering trials and process improvement projects to update global Powertrain Standards and the Bill of Process (BOP).

· Education: Bachelor’s degree in Engineering (Mechanical, Electrical, Manufacturing, Mechatronics, or related field).

· Experience: Professional experience in manufacturing or quality engineering within power electronics, powertrain systems (ICE or Electrification), or advanced electronics manufacturing, including participation in new program launches within GPDS environments.

· Technical Knowledge: Strong knowledge of Failure Mode Avoidance tools including PFMEA, Control Plans, SCCAF, and Error Proofing Matrices (EPM). Solid understanding of Bill of Process (BOP), manufacturing feasibility, and equipment procurement/validation.

· Inspection & Process Expertise: Demonstrated experience validating and analyzing soldering and welding processes using laboratory and inline inspection systems (AOI, AXI, CT inspection), including:

•  Vacuum Soldering
  • CT inspection and defect analysis
  • Solder wetting evaluation
  • Void detection and analysis
  • Bond line thickness control
  • Excess solder / solder bleed-out identification
• Laser Welding
  • Destructive validation methods
  • Weld depth penetration analysis
  • Weld length verification
  • Weld inspection area definition and validation
• Selective Soldering
  • Pin protrusion evaluation
  • Percentage of land area covered with wetted solder on secondary side (solder source side)
  • Wetting on solder source side of lead and barrel
  • Excess solder defects (solder balls)
  • Bridging defects
  • Solder webbing / splashes
  • Solder fracture / blow holes
  • Solder connection wetting angle evaluation
  • Non-wetting conditions
  • Solder volume control
  • Vertical fill validation

· Project Management: Proven ability to manage program deliverables, timing plans, and supplier technical evaluations, while supporting program budget tracking and investment efficiency.

· Language Skills: Advanced proficiency in English (written and verbal) to support global reporting, technical documentation, and cross-functional collaboration.

· Leadership & Collaboration: Strong communication and technical leadership skills with the ability to work across product engineering, manufacturing, quality teams, and suppliers to resolve complex engineering and quality challenges.