Lead Development Engineer

Lead Handles Development EngineerDepartment: Body Exterior / Handles, Locks & Mechanisms (HLM)Location: Dearborn, MichiganScheduleFully onsiteLong-term contractual assignmentOnsite or video interviewSupplier and Ford plant visits as neededTravelTravel may be required during the production build phasePotential locations include Metro Detroit and MexicoTrips may last approximately 1 to 2 weeksTravel is expected primarily once production or manufacturing beginsContract Length: Approximately 18 Months, with potential extensionPosition OverviewClient is seeking four Lead Handles Development Engineers to lead the development of exterior and interior door-handle systems across several current production programs.Each engineer will own a distinct handle architecture and its related variants. The role focuses on re-engineering existing handle designs with new supplier partners rather than developing entirely new mechanisms from the ground up.The engineer will lead a strategic supplier through an accelerated “go-fast” development process, moving the design through production readiness. This includes product improvement, design enhancements, supplier onboarding, technical development, validation, production tooling, PPAP, and final production release.The engineer will also work with affected cross-functional Ford teams to ensure interface requirements are identified and achieved, including requirements associated with latching, closure subsystems, and electrical components.Components SupportedExterior door handlesInterior door handlesDoor opening systemsHandle mechanismsLatching interfacesClosure subsystem interfacesMicroswitchesSmall electrical harnessesEach of the four engineers will lead a different handle architecture or commodity and work with different supplier partners.Key ResponsibilitiesLead suppliers through accelerated development of new handle opening systemsManage suppliers throughout product-development stagesDevelop and release components ready for production toolingEnsure tooled components are validated according to PPAP requirementsMaintain project timing and activity plansDrive compliance with milestone deliverablesKeep Ford management informed of progress, risks, and roadblocksWork closely with suppliers to develop product designsTrack delivery milestones and planning toward scheduled PPAPPerform design, CAD, and drawing reviewsCoordinate analytical verification activities, including:SimulationEngineering calculationsTolerance stack-upsTesting and evaluationReview product designs for compliance with engineering principles, requirements, company standards, and specificationsUtilize health charts and checklists to assess design complianceCoordinate technical-development and scheduling activitiesResolve engineering design and testing issuesIntegrate product, process, and lessons-learned concerns into the FMEACoordinate supplier validation testingReview supplier test reportsCoordinate Ford vehicle-level and subsystem validation testingCommunicate with internal and external technical teamsPrepare interim and final project reportsCreate and present technical presentationsRelease components for production through WERSSupport production through SREA and AlertsManage supplier design data within Ford systems and foldersMaintain CAD files, drawings, and CAE modelsCollaborate with electrical, latching, closure, and other cross-functional teamsVisit supplier and Ford manufacturing facilities during production build activitiesRequired SkillsMechanism DevelopmentMechanisms DevelopmentExterior Door HandlesInterior Door HandlesDoor MechanismsLatching SystemsHandle Opening SystemsMechanism HardwareProduct ImprovementDesign EnhancementsMaterials and ManufacturingEngineering PlasticsSteelPlastic MoldingMetal StampingsCastingsManufacturing ProcessesDesign for ManufacturingDesign for AssemblyDFMDFACAD and Product DataCATIA V5CATIA V6TeamcenterENOVIACAD ReviewsDrawing ReviewsBasic Design WorkSupplier Design Data ManagementQuality and ValidationDFMEABoundary DiagramsP-DiagramsRDMInterface MatrixDVP&RDOEPPAPSPC MethodsStatistical AnalysisGD&TProblem SolvingSix Sigma Tools5D8D6-PanelRelease and Production SupportWERSSREAAlertsProduction ReleaseProduction SupportSupplier ValidationVehicle ValidationSubsystem ValidationBusiness ToolsMicrosoft ExcelMicrosoft WordMicrosoft PowerPointRequired Experience10+ years of mechanisms development experienceExperience with latching, handles, exterior mechanisms, or similar mechanism hardwareAutomotive industry experienceOEM experience preferred, particularly with Ford, General Motors, or StellantisSupplier experience may be considered when it includes latch or door-mechanism developmentExperience managing suppliers through product developmentExperience leading suppliers through design and manufacturing readinessExperience reviewing product designs, CAD, and engineering drawingsStrong knowledge of engineering plastics and steelKnowledge of manufacturing processes, including:MoldingStampingCastingExperience leading tolerance-analysis studiesExperience with DFMEA, DVP&R, DOE, GD&T, DFM/DFA, SPC, and statistical analysisExperience releasing components for productionStrong written and verbal communication skillsAbility to work in CATIA V5/V6 and Teamcenter/ENOVIAProficiency with Microsoft Office toolsPreferred ExperienceExterior door-handle systemsInterior door-handle systemsAutomotive latching systemsDoor mechanismsExterior mechanismsWater-management designSealing designGreasesPainted plasticsMicroswitchesSmall electrical harnessesSupplier onboardingOEM Design Release EngineeringProduct-improvement programsExisting-product re-engineeringProduction toolingSupplier manufacturing launchesFord systems and processesPreferred Tolerance-Analysis ToolsC-Tol3DCSEnventiveVSAPreferred CAE ToolsADAMSWorking ModelCATIA FEAHyperMesh