Manufacturing Engineer – Fastening Systems at Ford Pro · Chennai

Support the development, validation, and optimisation of fastening and assembly systems for Engine and Transmission manufacturing within Powertrain Operations. The role focuses on fastening process design, equipment specification, quality improvement, new model launches, and manufacturing excellence while ensuring safety, quality, and cost objectives are achieved.

Ford Powertrain Manufacturing Engineers contribute to the design and production of advanced engine and transmission systems. This role is responsible for developing and implementing fastening and assembly processes that support safe, efficient, and high-quality manufacturing operations.

The engineer will work closely with Product Design, Manufacturing, Quality, Purchasing, and suppliers to ensure robust fastening solutions, assembly feasibility, and successful program launches. The position also supports continuous improvement initiatives and manufacturing innovation through Lean Manufacturing and Six Sigma methodologies.

Responsibilities

Process Design & Development

• Develop and optimise engine/transmission assembly process flows, line layouts, and workstation designs.
• Design assembly stations with a strong focus on safety, ergonomics, and manufacturability.
• Develop fastening process sheets, work instructions, and standard operating procedures (SOPs).
• Support new model launches, engineering changes, and process improvements.
• Evaluate assembly feasibility and incorporate Design for Manufacturing (DFM) and Design for Assembly (DFA) principles.

Fastening System Engineering

• Design and specify fastening systems including bolts, screws, rivets, clips, adhesives, and welds.
• Develop and validate fastening parameters including torque-to-yield, clamp load, and joint integrity requirements.
• Plan and execute fastening validation activities including torque-tension, tensile, and fatigue testing.
• Analyse fastening failures and develop corrective actions to improve system reliability.

Equipment & Tooling

• Select and specify fastening equipment including torque tools, automated fastening systems, and error-proofing solutions.
• Support installation, commissioning, and process validation activities.
• Coordinate with suppliers regarding fastener sourcing, qualification, and quality performance.

Quality & Continuous Improvement

• Conduct root cause analysis for fastening-related quality concerns including loose fasteners, cross-threading, and joint failures.
• Perform Process Failure Mode and Effects Analysis (PFMEA) and support Control Plan development.
• Lead Lean Manufacturing, Kaizen, and Six Sigma initiatives to improve productivity and reduce waste.
• Provide technical support to manufacturing plants for process optimisation and issue resolution.

Safety & Compliance

• Ensure compliance with corporate, industry, and regulatory standards.
• Conduct manufacturing risk assessments and implement safety improvements.
• Apply applicable fastening standards including SAE, ISO, and IFI requirements.

Procurement & Documentation

• Prepare and issue Requests for Quotation (RFQs).
• Evaluate supplier quotations based on technical and commercial requirements.
• Support purchase order processing in accordance with procurement procedures.
• Manage OEM documentation including reliability and maintainability reports, spare parts lists, manuals, preventive maintenance plans, and final installation drawings.
• Track documentation delivery and resolve supplier documentation gaps.

Qualifications

Education

Diploma or Bachelor's Degree in:

• Mechanical Engineering
• Manufacturing Engineering
• Automotive Engineering
• Industrial Engineering
• Electrical Engineering

Experience

• 2–5 years of experience in manufacturing engineering, assembly engineering, or fastening systems engineering.
• Experience in engine, transmission, powertrain, automotive, or high-volume manufacturing environments preferred.
• Experience supporting new product launches and process implementation activities.

Technical Skills

• Strong understanding of engine/transmission assembly processes.
• Knowledge of fastener selection, torque-tension relationships, clamp load, and joint design principles.
• Experience with automated and robotic fastening systems.
• Familiarity with fastening validation techniques and audit tools.
• Proficiency in CAD tools such as CATIA and AutoCAD.
• Working knowledge of PFMEA, Control Plans, and GD&T.
• Understanding of Lean Manufacturing and Six Sigma methodologies.
• Strong problem-solving and root cause analysis skills.

Professional Skills

• Strong communication and presentation skills.
• Ability to work effectively within cross-functional teams.
• Effective project coordination and stakeholder management skills.
• Willingness to work shifts and relocate based on business and project requirements.