JOB DESCRIPTION

The CAE Manufacturing Engineer will be required to apply their knowledge of Finite Element Analysis methods as it applies to both internal combustion engine and Emotor manufacturing for both machining and assembly operations. In this role, the CAE engineer will have direct impact over the design and processing of powertrain components in current and future Ford products. Ideal candidates must navigate and drive change in a complex internal environment, challenging the status quo as we define an all-new way of manufacturing vehicles.

RESPONSIBILITIES

Drive the CAE process modelling requests enabling a framework for the cross functional teams to create robust machining and assembly processes. Conduct analysis, provide interpretation, communicate, and document simulation results. Ensure manufacturing feasibility for assembly and machining process designs, resulting in parts that can be machined or assembled by standard and best practice methods in support of new Powertrain program product launches. These roles include and are limited to the following:

• Provide technical support to Product Development (PD) Component Program Module Teams (CPMT's) and coordinate process design between Product Engineering, PTME - Machining and Assembly, and external machining suppliers to assure 'design for manufacturing feasibility' of new Powertrain Machining and Assembly Methods.
• Support the Digital Preassembly 5 (DPA5) process through the development of component Manufacturing Design Specifications (MDS) and Manufacturing Process Specifications (MPS). Complete Manufacturing Assessments.
• Support simultaneous engineering and feasibility engineering studies among product engineering, manufacturing engineering, and supplier organizations.
• Support supplier selection evaluation process through manufacturing assessments and assist Purchasing in the evaluation, development, and selection of suppliers and subcontractors.
• Conduct clamping deformation analysis and communicate results to fixture supplier, driving robust fixture design.
• Support Machining Process engineers for natural frequency vs. cutting frequency analysis, face milling analysis, cylinder bore boring roundness analysis, valve seat machining deformation, flat and cylindrical surface stiffness, dynamic stiffness analysis, face milling force and burr prediction.
• Support assembly process engineers with press in analysis requests for valve seat and guide, axle tube, gear and bearing. Conduct bolt mounting deformation analysis, contact simulation, and staking analysis for applicable components.
• Evaluate innovative and disruptive emerging processes and material technologies for potential application to Ford products.
• Support Product Engineering in the selection and specification of component materials and test procedures.
• Assist Ford manufacturing plants, as required, in resolving significant engineering issues and achieving continuous improvement for both new programs and current production.
• Provide technical support, as required, to Purchasing (Component Buyers and Supplier Technical Assistance) involving the resolution of machining and assembly methods related to productivity and quality issues of external suppliers.

• Bachelor of Science/Engineering; MBA/MS preferred - Chemical/Electrical/Mechanical or Metallurgy/Materials Science.
• 5+ years prior experience with Machining CAE, preferably for powertrain applications.
• Strong communication skills, both written and oral.
• Working level knowledge of Assembly Operations.
• Machining fundamentals and process understanding of common machining operations including turning, boring, milling, drilling, reaming, grinding
• Knowledge of linear, elastic, and plastic deformation and analysis methods
• Working level knowledge of tooling, work holding, and fixturing.
• Knowledge of powertrain materials, steel, cast iron, CGI, and aluminum alloys.
• Understanding of finite element analysis including simulation software; SimCenter, Altair, NASTRAN, Abaqus, Jupiter, Thirdwave systems, and MATLAB.

• Excellent problem-solving skills and the ability to make decisions in a fast paced, dynamic environment.
• Exceptional communication and interpersonal skills to present, persuade, and collaborate at all levels of the organization.
• Highly motivated self-starter capable of driving change and influencing engineering decisions, with or without authority.
• Proven track record of delivering major product launches in an automotive manufacturing facility.
• Ability to work in a production setting and aid in troubleshooting of supplier equipment and processes. Possess practical problem-solving skill and the ability to address a variety of variables in situations where only limited standardization exists.
• Ability to travel both domestically and internationally.
  • Travel may be required from 25% of time.
• The lower end means working from home base (Dearborn) with minimum travel to Supplier/Vendors, Test facilities or out of state (of Michigan) Plants/Suppliers.
• The higher end of travel means supporting implementation/launch teams on site at the out of state (of Michigan) Plants/Suppliers. This could require traveling, working on-site at a Plant. Per HR guidelines, when supporting out of state you are allowed to travel home every other weekend.