Manufacturing Engineer – Fastening Systems

Ford Powertrain Manufacturing Engineers contribute to the design and production of advanced engine and transmission systems. This role is responsible for developing and implementing fastening and assembly processes that support safe efficient and high-quality manufacturing operations.

The engineer will work closely with Product Design Manufacturing Quality Purchasing and suppliers to ensure robust fastening solutions assembly feasibility and successful program launches. The position also supports continuous improvement initiatives and manufacturing innovation through Lean Manufacturing and Six Sigma methodologies.

Process Design & Development

• Develop and optimise engine/transmission assembly process flows line layouts and workstation designs.
• Design assembly stations with a strong focus on safety ergonomics and manufacturability.
• Develop fastening process sheets work instructions and standard operating procedures (SOPs).
• Support new model launches engineering changes and process improvements.
• Evaluate assembly feasibility and incorporate Design for Manufacturing (DFM) and Design for Assembly (DFA) principles.

Fastening System Engineering

• Design and specify fastening systems including bolts screws rivets clips adhesives and welds.
• Develop and validate fastening parameters including torque-to-yield clamp load and joint integrity requirements.
• Plan and execute fastening validation activities including torque-tension tensile and fatigue testing.
• Analyse fastening failures and develop corrective actions to improve system reliability.

Equipment & Tooling

• Select and specify fastening equipment including torque tools automated fastening systems and error-proofing solutions.
• Support installation commissioning and process validation activities.
• Coordinate with suppliers regarding fastener sourcing qualification and quality performance.

Quality & Continuous Improvement

• Conduct root cause analysis for fastening-related quality concerns including loose fasteners cross-threading and joint failures.
• Perform Process Failure Mode and Effects Analysis (PFMEA) and support Control Plan development.
• Lead Lean Manufacturing Kaizen and Six Sigma initiatives to improve productivity and reduce waste.
• Provide technical support to manufacturing plants for process optimisation and issue resolution.

Safety & Compliance

• Ensure compliance with corporate industry and regulatory standards.
• Conduct manufacturing risk assessments and implement safety improvements.
• Apply applicable fastening standards including SAE ISO and IFI requirements.

Procurement & Documentation

• Prepare and issue Requests for Quotation (RFQs).
• Evaluate supplier quotations based on technical and commercial requirements.
• Support purchase order processing in accordance with procurement procedures.
• Manage OEM documentation including reliability and maintainability reports spare parts lists manuals preventive maintenance plans and final installation drawings.
• Track documentation delivery and resolve supplier documentation gaps.

Education

Diploma or Bachelors Degree in:

• Mechanical Engineering
• Manufacturing Engineering
• Automotive Engineering
• Industrial Engineering
• Electrical Engineering

Experience

• 25 years of experience in manufacturing engineering assembly engineering or fastening systems engineering.
• Experience in engine transmission powertrain automotive or high-volume manufacturing environments preferred.
• Experience supporting new product launches and process implementation activities.

Technical Skills

• Strong understanding of engine/transmission assembly processes.
• Knowledge of fastener selection torque-tension relationships clamp load and joint design principles.
• Experience with automated and robotic fastening systems.
• Familiarity with fastening validation techniques and audit tools.
• Proficiency in CAD tools such as CATIA and AutoCAD.
• Working knowledge of PFMEA Control Plans and GD&T.
• Understanding of Lean Manufacturing and Six Sigma methodologies.
• Strong problem-solving and root cause analysis skills.

Professional Skills

• Strong communication and presentation skills.
• Ability to work effectively within cross-functional teams.
• Effective project coordination and stakeholder management skills.
• Willingness to work shifts and relocate based on business and project requirements.