Process Engineer, Energy

About the Role

Ford Energy is seeking a Process Engineer to play a critical role in launching and scaling operations at their Glendale Junction facility. This is a high-impact, startup role within a legacy manufacturing powerhouse, dedicated to accelerating U.S. energy independence through battery energy storage systems (BESS).

Key Responsibilities

• Greenfield Production Excellence & Manufacturing Systems
• Lead the design and implementation of the Ford Energy Production System (FEPS), focusing on standardized work, line balancing, and optimized workstation layouts.
• Develop labor standards and manpower plans for cell, module, and pack assembly to maximize utilization and efficiency.
• Drive continuous improvement in safety, quality, and productivity across all production lines.
• Analyze production constraints and perform equipment cycle time studies to optimize throughput, Jobs Per Hour (JPH), and First Time Through (FTT) quality.
• Design and refine station layouts using CAD, incorporating tooling, material presentation, and error-proofing (Poka-Yoke) for zero-defect manufacturing.
• Conduct ergonomic job evaluations and implement workstation designs that meet high safety standards in automated, high-speed production environments.
• Manage procurement, commissioning, capability validation, and debugging of new production equipment, including vendor site buy-offs.
• Collaborate with Product Design, suppliers, and manufacturing teams to develop optimal process strategies, including gauging, torque strategies, and in-process testing.
• Leadership & Culture
• Embrace the Gemba philosophy: Regularly engage on the production floor to identify bottlenecks, verify standardized work adherence, and solve problems in real time.
• Develop "Leaders as Teachers": Mentor Production and Operations teams on lean principles, including takt time vs. cycle time and waste elimination.
• Remove barriers proactively in the launch phase to ensure seamless equipment buy-offs and successful Start-Of-Production (SOP).
• Act as a catalyst who identifies gaps and proposes solutions before they become issues.
• Partner cross-functionally with Manufacturing Engineering, Quality, and Operations to achieve Ford Energy’s Vision, Mission, and Values.
• Strategic Management & Integrity
• Establish and track Production Key Performance Indicators (KPIs), including OEE (Overall Equipment Effectiveness), scrap rates, and FTT quality.
• Lead cross-functional initiatives in quality to achieve "No Faults Forward" and zero defects on the production line.
• Coordinate quality containment actions, dock holds, and special checks to eliminate any impact on the customer, maintaining detailed traceability records.
• Manage quality documentation, including FTT, 8Ds, Scrap, and Dock Audits.
• Lead 8D root-cause resolution for warranty and battery operations concerns in collaboration with Quality, MP&L, and Assembly teams.
• Manage and direct statistical process control (SPC) activities, execute measurement systems analysis (MSA), and variable data analysis to drive process capability (Control Plans).
• Review rejected parts for quality integrity, determine corrective actions, and issue daily quality reports.
• Manage the Engineering Change Management (ECM) process for the production floor, ensuring all process modifications are documented, and process sheets/instructions are updated accurately.

Requirements & Tech Stack

• Technical Knowledge: Advanced proficiency in AutoCAD, MODAPTS, and manufacturing simulation tools.
• Familiarity with engineering change and release systems (e.g., WERS, CORA, or similar).

Qualifications

• Education: Bachelor’s degree in Engineering (e.g., Mechanical, Electrical, Chemical, Industrial, Manufacturing, or a related engineering field).
• Experience: 0-2 years of progressive experience in Industrial Engineering or Manufacturing Engineering within a high-volume production environment.
• Leadership Attributes:
• Resilient leader demonstrating composure and sound judgment in a high-pressure startup production environment.
• Collaborative influencer skilled in building trust and aligning cross-functional teams on production targets, labor standards, and workstation design.
• Throughput expert skilled in capacity modeling, bottleneck identification, and high-volume automated manufacturing.
• Integrity-focused, upholding standardized work and engineering rigor.
• Strategic visionary translating production data into scalable manufacturing strategies.
• Decisive under pressure, making rapid, data-driven decisions during line balancing and production ramp-up.
• Adaptable, leading effectively in an evolving startup environment and supporting a 24/7 operation as needed.

Even Better If You Have

• Experience in Greenfield site development or high-volume automotive, battery, or electronics manufacturing.
• Lean Manufacturing and/or Six Sigma certification (Green Belt or Black Belt).
• Experience with 8D, 5-Why analysis, DMAIC/DMADV methodologies, and lean tools (5S, Kanban, Poka-Yoke, Value Stream Mapping).
• Strong communication, collaboration, and team-building skills.
• Passion for energy systems and U.S. energy independence.

Location & Travel

• U.S. with domestic travel.