eMotor CE1 Rotor Process Engineer Planta Ford Irapuato

We are seeking a highly skilled Process Engineer to lead and control the Rotor Balancing and Aluminum Die Casting processes for the eMotor this specialized role you will ensure product quality and process stability for aluminum rotor components by managing rotor balancing (static and dynamic) optimizing high-pressure aluminum die casting parameters and utilizing advanced metallurgical and simulation tools. Supported by quality engineering tools (DFMEA PFMEA Control Plan Process Illustration Part Print and Reaction Plan) you will implement the SPC strategy reduce scrap due to common-cause variation manage casting tooling/molds and report monthly process capability while maintaining close collaboration with Production Maintenance Quality PTME OEM and Suppliers.

• Rotor Balance Process Control: Lead stabilize and control the rotor balancing process (static and dynamic including two-plane balancing) for aluminum rotor components ensuring strict balance targets and tolerances are met.

• Aluminum Die Casting & Foundry Management: Optimize high-pressure die casting (HPDC) and induction melting parameters (melting injection pressure speed cooling and solidification) to minimize porosity density variations and geometric defects that impact rotor balance.

• Casting Simulation & Optimization: Set up run and interpret aluminum casting simulations (using MAGMA ProCAST or equivalent) to optimize fill flow porosity and solidification behaviors.

• Mold & Tooling Lifecycle Management: Manage inspect and maintain casting molds and tooling ensuring preventive maintenance is performed downtime is minimized and tooling tolerances are preserved.

• Quality & Metallurgical Analysis: Perform non-destructive testing (interpreting X-ray results for porosity misruns and inclusions) mass spectrometry for alloy composition analysis and metallographic microscope analysis to identify microstructure defects.

• Gauges & Measurement Systems: Implement and maintain specialized gauges presses and measurement devices to verify GD&T tolerances aluminum density and overall rotor quality.

• Personnel Training: Train coach and certify production operators and technicians on rotor balance procedures die casting operation gauge usage and reaction plans.

• Technical & Quality Documentation: Continually develop update and validate DFMEA PFMEA Control Plan Process Illustration and Part Print (GD&T drawings) focusing on rotor-specific balance and casting variations.

• SPC Strategy and Reporting: Implement and oversee the SPC strategy (sampling design control charts variability analysis and Cp/Cpk Pp/Ppk calculation) using Quality Works (or similar tools) and prepare monthly capability reports.

• Monitoring and Improvement of Quality Metrics: Regularly monitor and optimize KPIs such as First Time Through (FTT) and Rolled Throughput Yield (RTY) focusing on reducing scrap by addressing common-cause variation.

• Engineering Change Management and Reaction Plans: Lead Engineering Change Management (MTC) and structure robust reaction plans for rotor process deviations.

• Problem Solving and Lean Manufacturing: Apply structured methodologies (Global 8D Six Sigma or equivalent) and Lean tools (Value Stream Mapping VSM 5Ss SMED etc.).

• Process Audits: Actively participate in process and quality system audits (such as ISO 9001 and IATF 16949) to ensure full compliance.

• Cross-Functional Collaboration: Work in synergy with Production Maintenance Quality PTME and external suppliers to resolve technical issues and meet project milestones.

• Professional Reporting: Prepare professional-grade reports and presentations to clearly explain balance casting and metallurgical investigations to management and stakeholders.

Education

• Bachelors degree in Engineering (Mechanical Industrial Materials/Metallurgy Mechatronics or a related field).

Experience

• Strong demonstrable experience in rotor balancing (static/dynamic) and aluminum die casting processes preferably for rotor components electric motors or related high-precision automotive applications.
• Experience with mold/tooling design reading mold drawings and maintenance for aluminum casting and/or casting die tooling.
• Experience coordinating balance-related activities across multiple production lines or modules is highly valued.

Languages

• Fluent English (B2/C1 level equivalent) with excellent technical communication reading and writing skills.

Technical Knowledge

• Rotor Balancing: In-depth understanding of rotor balancing (static/dynamic two-plane) and balance quality targets; practical experience using balancing machines and vibration analysis instruments.

• Casting Simulation: Proficiency with aluminum casting simulation software (MAGMA ProCAST) to analyze fill flow porosity and solidification.

• High-Pressure Die Casting (HPDC) & Foundry: Deep understanding of HPDC fundamentals aluminum casting (gating risers porosity sources defect management) and induction melting processes (induction furnaces melting control alloying).

• Mold & Tooling: Mold/tooling design reading mold drawings mold tolerances and tooling preventive maintenance/lifecycle management.

• Analysis & Testing:

  • Non-destructive testing (NDT): experience operating and/or interpreting X-ray results for casting defects.
  • Mass spectrometry: knowledge of Optical Emission Spectroscopy (OES) or ion-based techniques (ICP-MS) for alloy composition.
  • Metallography: microscope analysis for identifying porosity aluminum defects and interpreting microstructures.
  • Aluminum density: understanding of density variations and their impact on weight tolerances and rotor balance.

• Equipment & Tools: Experience working with presses (die casting and metal forming presses) and Quality Works (or similar quality data management software).

• Quality & Engineering Standards:

  • Proficiency in Geometric Dimensioning and Tolerancing (GD&T).
  • Advanced ability to interpret technical drawings (Part Prints) and Process Illustrations.
  • Mastery of Core Tools (DFMEA PFMEA Control Plan MSA) and SPC / Process Capability (Cp/Cpk Pp/Ppk).
  • Structured problem-solving methodologies (Global 8D Six Sigma or equivalent).
  • Lean Manufacturing tools (Value Stream Mapping Poka Yoke Error Proofing SMED).
  • Knowledge of ISO 9001 and IATF 16949.
  • Ergonomics applied to balancing and manufacturing stations.
  • Monitoring and improving quality KPIs (FTT RTY).

Soft Skills

• Analytical thinking and complex problem-solving abilities.
• Leadership proactivity and a results-driven mindset.
• Strong communication and technical writing skills.
• Ability to work effectively in cross-functional multidisciplinary teams.

DISCLAIMER: Ford Motor Company is an Equal Opportunity Employer as we are committed with a diverse workforce and do not discriminate against any employee or applicant for employment because of race color sex age national origin religion sexual orientation gender identity and/or expression status as a veteran and basis of disability.