We are seeking a highly skilled Process Engineer to lead and control the Rotor Balancing and Aluminum Die Casting processes for the eMotor project. In 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

• Bachelor’s 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.