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Ford Motor Company · 9 hours ago

Cell-to-Pack Technical Specialist

Long Beach, CA

Full-time

Hybrid

Senior Level, Lead/Staff

8+ years exp

Ford Motor Company is rapidly scaling next-generation battery manufacturing, including cell-to-pack architectures for electric vehicles. They are seeking a Cell-to-Pack Technical Specialist to provide technical leadership and ensure the manufacturing feasibility of groundbreaking battery products while collaborating with product and technology development teams.

AutomotiveAutonomous VehiclesManufacturingTransportation

No H1B

Responsibilities

Establish a complete battery manufacturing process, for cell-to-pack assembly system. This includes designing the production line layout and implementing all manufacturing procedures and follow through to launch at the factory

Drive design for manufacturing (DFM) for new cell-to-pack battery products by leading simultaneous engineering efforts with product, purchasing, and supplier teams, ensuring manufacturing feasibility

Develop competitive, high-ROI automation solutions by collaborating with technology partners to improve productivity

Collaborate with industrial engineering to define cycle time, OEE, and other key performance indicators (KPIs), and develop optimal operating and labor strategies to meet these targets

Develop and maintain complete documentation packages for new manufacturing processes. This includes detailed process instructions, technical drawings, preventative maintenance plans, spare parts lists, and operator training manuals

Proactively manage project schedules, budgets, and change requests to ensure projects are delivered on time, within budget, and to the required quality standards

Lead the development of quality control methods, including PFMEA, gauge R&R studies, and inspection procedures, creating a comprehensive control plan aligned with the overall quality strategy

Define critical-to-quality (CTQ) characteristics, prevention/detection methods, and inspection acceptance criteria; establish inline and offline gauging strategies

Ensure compliance with Ford’s safety standards and industry best practices for high voltage battery manufacturing

Partner with cell and pack product design teams on the following: Influencing Design for Manufacturability (DFM): You will provide early input to design teams, collaborating to simplify designs, optimize material selection, and reduce manufacturing complexities and costs

Addressing Tolerance Stack-up: You will analyze critical dimensions and tolerances, predict potential assembly issues, and recommend practical tolerances that balance design needs with manufacturing feasibility

Ensuring Overall Manufacturability: You will develop and validate manufacturing processes, conduct pilot runs, and provide technical support for new product launches to ensure smooth and efficient production transitions

Communicate effectively with team members, stakeholders, and OEM partner(s) to ensure project success and timely delivery of products

Support problem-solving activities (8D, 5-Why, Ishikawa) for build issues, field returns, and validation of test failures

Support pilot builds, pre-production, and launch events at global manufacturing sites

Develop documentation and training for plant teams: process instructions, troubleshooting guides, maintenance best practices, and safety procedures

Drive continuous improvement of OEE, cycle time, yield, scrap, and consumable usage

Benchmark industry best practices and emerging technologies in battery cell-to-pack assembly and recommend adoption paths for Ford

Qualification

Battery manufacturing processesProcess developmentAutomation solutionsMechanical designData analysisCell-to-pack assemblyQuality control methodsProject managementCollaborationProblem-solving

Required

Bachelor's degree in Mechanical Engineering or relevant engineering discipline

8+ years experience developing new automated manufacturing processes in the battery and/or automotive industry implementing large scale projects as a Manufacturing Engineer or Project Manager

Demonstrated experience with: Developing and optimizing welding or joining processes (laser, resistance, TIG/MIG, ultrasonic, etc.)

Metallurgical evaluation of welds (microstructure, defects, joint design considerations)

Running structured experiments and analyzing data (DoE, regression, statistical analysis)

Understanding or experience in cell-to-pack assembly processes (cylindrical or prismatic form factor preferred)

Experience designing mechanical equipment, fixturing, and tooling, through use of digital tools and methods with clear understanding of tolerance stack up and GD&T

Must have deep knowledge and understand of assembly systems and process flow, with the ability to identify and utilize new technologies to improve manufacturing processes

Proficiency with engineering tools and systems such as: CAD tools (e.g., CATIA, NX, 3DX) for joint and fixture reviews

Data analysis tools (e.g., Minitab, JMP, Python, MATLAB, Excel)

Quality tools (PFMEA, control plans, SPC, 8D, 5-Why)

Preferred

Master's degree in Mechanical Engineering or relevant engineering discipline

10+ years experience developing new automated manufacturing processes in the battery and/or automotive industry implementing large scale projects as a Manufacturing Engineer or Project Manager