Production Design Engineer - PVT

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?

Ford of Canada's operations include a national headquarters, three vehicle assembly and engine manufacturing plants, three parts distribution centres, and three Connectivity and Innovation centres. Ford employs approximately 7,000 people in Canada, while an additional 18,000 people are employees in the more than 400 Ford and Ford-Lincoln dealerships across the country. For more information, please visit www.careers.ford.com

At Ford’s Oakville Assembly Complex, we are expanding and retooling our vehicle operations like never before. This is more than just delivering a flawless new vehicle launch; it’s an opportunity to shape the future of vehicle manufacturing in Canada. Here is where cutting-edge manufacturing processes will bring to life vehicles that embody unparalleled performance and unwavering dependability. 

At Ford of Canada, we don’t just build vehicles; we craft the essential tools that empower businesses and individuals across the globe. Ford was built on the belief that freedom of movement drives human progress. As we look to the future and the changing needs of society, we are committed to becoming the world’s most trusted mobility company – delivering smart vehicles for a smart world. Join our team as we create tomorrow! We believe in putting people first, working together, and facing challenges head-on. Join us in creating vehicles that keep the world moving and forge a career defined by meaningful impact and innovation.

In this position... 

At Ford of Canada, we are shaping the future of mobility. We are seeking a dedicated Plant Vehicle Team (PVT) Engineer specializing in Vehicle Lighting, Water Leak Management, and Sealing Systems to join our team at Oakville Assembly Plant as we launch the highly anticipated Ford Super Duty truck.
As a PVT Engineer, you will serve as the 'first line of defense' for quality, focusing on exterior lighting systems, water leak management, and static/dynamic sealing performance. You'll collaborate across global product development teams, manufacturing operations, and suppliers to deliver industry-leading quality.

What you'll do...

The primary responsibilities for this position include but are not limited to:

Quality Ownership & Continuous Improvement

• Own lighting, water leak, and sealing quality objectives (R/1000 and CPU); resolve chronic and new warranty concerns related to lighting performance, water ingress, wind noise, and sealing durability
• Lead IRIS warranty analysis for lighting and sealing defects 
• Conduct root cause analysis addressing lighting assembly variability, water entry paths, seal interface failures, weatherstrip compression loads, drainage system blockages, and assembly-induced gaps
• Lead Variability Reduction Team (VRT) activities and utilize Ford manufacturing systems (GQRS, FPS) to meet quality performance standards

Problem Solving & Technical Analysis

• Lead cross-functional teams to resolve lighting, water leak, and sealing concerns and drive sustainable process improvements
• Prepare structured problem-solving documentation (8D, A3, 5-Why, Fishbone) using SIMPSN system
• Analyze key metrics including photometric performance, seal compression load data, water leak test results, wind noise measurements, drainage flow rates, and CMM dimensional data to identify trends and optimize processes
• Apply GD&T and tolerance stack concepts to support robust fixes for lighting alignment, seal interface management, and water management system performance

Plant Support & Issue Resolution

• Represent Product Development during urgent containment activities (Stop Ships/Builds, quality holds) related to lighting failures, water leaks, or sealing concerns
• Develop inspection and repair instructions for critical quality issues including lighting aim adjustments, water leak localization, seal replacements, and drainage system corrections
• Partner with manufacturing and quality teams to address EOL and FTT inhibitors related to lighting assembly, sealing installation integrity, and water leak audit performance
• Provide on-site support for static and dynamic water leak audits, wind noise evaluations, quality campaigns, and launch-related build concerns
• Utilize water leak detection methods (static water test, dynamic rain simulation, ultrasonic leak detection, dye tracing) to localize and resolve water entry concerns

Change Management & Product Launch

• Lead engineering commodity changes for lighting systems and sealing assemblies; manage cost reduction actions and oversee engineering trials
• Support Change Control activities by coordinating in-plant trials for lighting supplier changes, seal cross-section modifications, drainage path updates, and assessing impacts on sealing performance, quality, and production throughput
• Support launch teams through OK to Buy (OKTB) and resolve post-OKTB lighting, water leak, and sealing issues
• Issue Engineering Alerts and initiate Engineering Concerns for product changes targeting lighting regulatory compliance, sealing durability, water management performance, and corrosion protection objectives

Collaboration & Communication

• Present findings in plant quality meetings (FQR, DQR, VQR) representing lighting, water leak management, and sealing systems
• Collaborate with lighting and sealing suppliers to optimize assembly processes, evaluate seal compression and wear performance, and support maintenance strategies that minimize water ingress risk
• Work with internal teams (Product Development, Manufacturing Engineering, Plant Quality, STA) and external suppliers including lighting manufacturers, weatherstrip suppliers, and sealing system integrators
• Effectively escalate critical concerns through appropriate engineering forums

You'll have... 

Education- Bachelor's degree in Mechanical, Electrical, Materials, or Manufacturing Engineering or related discipline. (Successful candidates will be required to provide proof of degree completion for the highest level of education attained.  If the degree was obtained from a school outside of Canada, an Education Credential Assessment report showing Canadian equivalency is also required).

Experience

• 2+ years in Product Development, Quality, Manufacturing Engineering, or related operations involving lighting, water management, or sealing systems.
• Ability to travel to the US for short-term work assignments. 

Even better, you may have...

Education-Master's degree in an engineering discipline.

Experience

• Proficiency in vehicle lighting systems, static and dynamic sealing systems, and water leak diagnosis/resolution, including vehicle drainage systems, water entry path analysis, and sealing interface management.
• Experience with dimensional engineering and metrology systems, including Coordinate Measuring Machines (CMM), optical scanning, and Geometric Dimensioning and Tolerancing (GD&T), as well as knowledge of lighting optical design principles and photometric testing.
• Six Sigma certification (Black Belt or Green Belt) and proficiency in data analytics tools such as Excel, Minitab, JMP, or Python.
• Experience with Ford systems, including Global Quality Reporting System (GQRS), Ford Production System (FPS), Integrated Reporting and Information System (IRIS), and Single Integrated Manufacturing Project Status Network (SIMPSN).
• Advanced analytical and troubleshooting skills paired with a structured, results-oriented approach to problem-solving.
• Exceptional leadership, teamwork, and communication abilities; a self-starter capable of managing multiple priorities in a fast-paced environment.

This posting is for an existing vacancy within our team.

The expected annual salary range for this Ford of Canada position is $74,000.00 - $124,000.00 and individuals may be eligible to participate in our Annual Compensation bonus program.

We thank all candidates for their interest, but only those selected for an interview will be contacted.

Ford of Canada is an Equal Opportunity Employer and is committed to a culturally diverse workforce. Accommodations for applicants with disabilities throughout the recruitment, selection and/or assessment processes, where needed, are available upon request. Please inform Human Resources of the nature of any accommodation(s) that you may require.

Candidates for this position must be legally entitled to work in Canada. Ford Motor Company of Canada, Limited, does not sponsor work permit applications.

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