Process Engineer (gear Machining)

Ford · Auto · Sterling Heights, MI +1 · Manufacturing

Process Engineer at Ford focused on gear machining, ensuring manufacturing processes are stable, efficient, and meet automotive production standards. Responsibilities include supporting manufacturing engineering, driving continuous improvement, applying engineering principles, developing action plans for quality concerns, conducting process audits, performing job ergonomic evaluations, analyzing root causes, creating process documentation, delivering capable processes and tools, leading variability reduction and lean manufacturing initiatives, ensuring compliance to standards, and supporting ISO 14001. Requires experience in gear machining and manufacturing environments, with a preference for a Bachelor's Degree in Engineering and experience in lean manufacturing, Six Sigma, and specific problem-solving methodologies.

What you'd actually do

  1. Support Manufacturing Process Engineering activity
  2. Drive continuous improvement in safety, quality and productivity
  3. Apply engineering principles and analytical techniques to establish and continuously improve manufacturing processes and products
  4. Develop action plans as required to investigate and prioritize quality concerns and verify corrective actions on internal processes and supplier processes
  5. Lead and conduct process audits to ensure process discipline is consistent with guidelines

Skills

Required

  • 1+ year of Process Engineering experience
  • 1+ years of experience working in a manufacturing environment
  • 1+ years of experience with gear machining, blanking, hobbing, milling and auxiliary processes
  • High school diploma or GED

Nice to have

  • Bachelor’s Degree in Engineering
  • Effective oral and written communication skills
  • 2 or more years in the automotive industry
  • Lean Manufacturing and Six Sigma experience
  • 8D and 5Why corrective action and problem solving skills
  • Solid understanding of Lean Tools – 5S, Kanban, Poka-yoke, and Value Stream Mapping
  • Familiarity with DMAIC and DMADV (DFSS) Project Methodology experience
  • Knowledge of TQM and Kaizen Methods, FMEA, PPAP, and DOEs experience
  • Validated experience with Visual Factory Management

What the JD emphasized

  • gear machining
  • automotive production standards
  • operator safety
  • process documentation
  • manufacturing processes are stable, efficient, and capable
Read full job description

**In this position... **

  • Requires a deep understanding of specific manufacturing disciplines, particularly gear machining (blanking, hobbing, turning and milling). You will evaluate the ergonomics of various jobs to ensure operator safety and lead "Visual Factory" management to make production status and issues transparent to all team members.
  • Balances hands-on technical support—specifically involving gear machining with administrative oversight of process documentation. Ultimately, your goal is to ensure manufacturing processes are stable, efficient, and capable of meeting rigorous automotive production standards.

What you'll do...

· Support Manufacturing Process Engineering activity

· Drive continuous improvement in safety, quality and productivity

· Apply engineering principles and analytical techniques to establish and continuously improve manufacturing processes and products

· Develop action plans as required to investigate and prioritize quality concerns and verify corrective actions on internal processes and supplier processes

· Lead and conduct process audits to ensure process discipline is consistent with guidelines

· Conduct job ergonomic evaluations and deliver corrective actions as required

· Analyze root causes; engage in mapping and corrective actions.

· Create process and instruction sheets supporting quality methods and processes

· Deliver capable processes and tools

· Lead variability reduction and lean manufacturing initiatives and best practices

· Ensure compliance to Plant, Corporate, Governmental and Environmental standards

· Back up ISO 14001 compliance and support internal ISO auditing and compliance as required

· Support continuous improvement in safety, quality and productivity

· Identify throughput constraints and drive root cause improvements

You'll have...

  • High school diploma or GED
  • 1+ year of Process Engineering experience (can include co-op/internships)
  • 1+ years of experience working in a manufacturing environment (internship and coop experience will be considered)
  • 1+ years of experience with gear machining, blanking, hobbing, milling and auxiliary processes

Even better, you may have...

  • Bachelor’s Degree in Engineering preferred
  • Effective oral and written communication skills
  • 2 or more years in the automotive industry
  • Lean Manufacturing and Six Sigma experience
  • 8D and 5Why corrective action and problem solving skills
  • Solid understanding of Lean Tools – 5S, Kanban, Poka-yoke, and Value Stream Mapping
  • Familiarity with DMAIC and DMADV (DFSS) Project Methodology experience
  • Knowledge of TQM and Kaizen Methods, FMEA, PPAP, and DOEs experience
  • Validated experience with Visual Factory Management

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 builder…or all the above? No matter what you choose, we offer a work life that works for you, including:

· Immediate medical, dental, and prescription drug coverage

· Flexible family care, parental leave, new parent ramp-up programs, subsidized back-up childcare 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 Year’s Day

· Paid time off and the option to purchase additional vacation time.

For more information on salary and benefits, click here: https://fordcareers.co/GSRnon-HTHD

This position is a range of salary grades 6, 7 and 8.

This position is a salary grade 6 and ranges from $72,480-121,440.

This position is a salary grade 7 and ranges from $84,480-141,360.

This position is a salary grade 8 and ranges from $96,720-162,120.

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 committed to a culturally diverse workforce. 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.

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