Cell-to-Pack Technical Specialist

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, weu2019re all a part of something bigger than ourselves. Are you ready to change the way the world moves? In this position... Ford is rapidly scaling next-generation battery manufacturing, including cell-to-pack architectures for our future electric vehicles. We are seeking a Process Engineering Technical Specialist to provide technical leadership to 100+ engineers within our battery manufacturing organization and shape the production of the next generation of electric vehicles. In this role you will serve as a critical focal point for our product development teams, ensuring the manufacturing feasibility of groundbreaking battery products and act as a catalyst for innovation between our product and technology development teams and manufacturing engineering. You will directly influence the design and implementation of cutting-edge battery manufacturing processes from early concept through pilot line, launch, and high-volume production. You will benchmark industry best practices and emerging technologies in cell-to-pack battery assembly and recommend adoption paths for Ford. What you'll do... Process Development & Industrialization + Establish a complete battery manufacturing process, for cell-to-pack assembly system. This includes designing the production line layout and implementing all manufacturing procedures and follow through to launch at the factory. + Drive design for manufacturing (DFM) for new cell-to-pack battery products by leading simultaneous engineering efforts with product, purchasing, and supplier teams, ensuring manufacturing feasibility. + Develop competitive, high-ROI automation solutions by collaborating with technology partners to improve productivity. + Collaborate with industrial engineering to define cycle time, OEE, and other key performance indicators (KPIs), and develop optimal operating and labor strategies to meet these targets. + Develop and maintain complete documentation packages for new manufacturing processes. This includes detailed process instructions, technical drawings, preventative maintenance plans, spare parts lists, and operator training manuals. + Proactively manage project schedules, budgets, and change requests to ensure projects are delivered on time, within budget, and to the required quality standards. Quality, Safety, and Compliance + Lead the development of quality control methods, including PFMEA, gauge R&R studies, and inspection procedures, creating a comprehensive control plan aligned with the overall quality strategy. + Define critical-to-quality (CTQ) characteristics, prevention/detection methods, and inspection acceptance criteria; establish inline and offline gauging strategies. + Ensure compliance with Fordu2019s safety standards and industry best practices for high voltage battery manufacturing. Cross-Functional Collaboration + Partner with cell and pack product design teams on the following: + Influencing Design for Manufacturability (DFM) : You will provide early input to design teams, collaborating to simplify designs, optimize material selection, and reduce manufacturing complexities and costs. + Addressing Tolerance Stack-up: You will analyze critical dimensions and tolerances, predict potential assembly issues, and recommend practical tolerances that balance design needs with manufacturing feasibility. + Ensuring Overall Manufacturability: You will develop and validate manufacturing processes, conduct pilot runs, and provide technical support for new product launches to ensure smooth and efficient production transitions. + Communicate effectively with team members, stakeholders, and OEM partner(s) to ensure project success and timely delivery of products. + Support problem-solving activities (8D, 5-Why, Ishikawa) for build issues, field returns, and validation of test failures. + Travel to domestic and international manufacturing facilities to collaborate with team members, oversee vendor runoff, and in-plant runoff. Launch & Continuous Improvement + Support pilot builds, pre-production, and launch events at global manufacturing sites. + Develop documentation and training for plant teams: process instructions, troubleshooting guides, maintenance best practices, and safety procedures. + Drive continuous improvement of OEE, cycle time, yield, scrap, and consumable usage. + Benchmark industry best practices and emerging technologies in battery cell-to-pack assembly and recommend adoption paths for Ford. You'll have... + Bacheloru2019s degree in Mechanical Engineering or relevant engineering discipline. + 8+ years experience developing new automated manufacturing processes in the battery and/or automotive industry implementing large scale projects as a Manufacturing Engineer or Project Manager. + Demonstrated experience with: + Developing and optimizing welding or joining processes (laser, resistance, TIG/MIG, ultrasonic, etc.). + Metallurgical evaluation of welds (microstructure, defects, joint design considerations). + Running structured experiments and analyzing data (DoE, regression, statistical analysis). + Understanding or experience in cell-to-pack assembly processes (cylindrical or prismatic form factor preferred). + Experience designing mechanical equipment, fixturing, and tooling, through use of digital tools and methods with clear understanding of tolerance stack up and GD&T. + Must have deep knowledge and understand of assembly systems and process flow, with the ability to identify and utilize new technologies to improve manufacturing processes. + Proficiency with engineering tools and systems such as: + CAD tools (e.g., CATIA, NX, 3DX) for joint and fixture reviews. + Data analysis tools (e.g., Minitab, JMP, Python, MATLAB, Excel). + Quality tools (PFMEA, control plans, SPC, 8D, 5-Why) Even better, you may have... + Master's degree in Mechanical Engineering or relevant engineering discipline. + 10+ years experience developing new automated manufacturing processes in the battery and/or automotive industry implementing large scale projects as a Manufacturing Engineer or Project Manager. Additional Details + Travel: Up to 20u201330% travel will be required to support pilot builds, pre-production, and launch events at Ford manufacturing sites and supplier facilities, outside of California. + Work Environment: Office location will be embedded with the Long Beach based product design team, but representing the manufacturing engineering team based in Dearborn, MI. 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 builderu2026or 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 Yearu2019s Day + Paid time off and the option to purchase additional vacation time. This position is a leadership level 6. For more information on salary and benefits, click here ( 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. #LI-Onsite #LI-DP1 Requisition ID : 55985

Created: 2025-12-11