Lead Handles Development Engineer

Overview
Ford is seeking high‑caliber Lead Engineers to drive the end‑to‑end development of exterior and interior door handle systems across multiple current production vehicle programs. This role partners closely with Ford's supplier base to re‑engineer handle mechanisms using existing architectures with new suppliers, delivering production‑ready solutions on an accelerated timeline.
Each Lead Engineer will own a specific handle architecture and its variants, serving as the primary technical point of contact from concept through production launch.



Key Responsibilities

• Lead supplier partners through an accelerated ("go‑fast") design‑to‑production development process for door handle opening systems
• Own overall technical delivery for assigned handle architectures, including exterior and interior handle mechanisms
• Manage suppliers through all development phases, ensuring parts are released for production tooling
• Ensure all tooled parts are validated and approved per PPAP requirements
• Drive program timing, milestone compliance, and deliverable readiness; proactively identify and resolve risks
• Communicate program status, issues, and recovery plans to Ford management and cross‑functional stakeholders

Essential Duties:

• Collaborate closely with suppliers to develop robust, production‑ready designs
• Track development plans and delivery milestones to achieve scheduled PPAP timing
• Perform and lead design, CAD, and drawing reviews
• Coordinate and review analytical verification activities (simulation, calculations, tolerance stack‑ups, T&E)
• Ensure designs comply with engineering best practices, Ford standards, and system requirements (Health Charts / Checklists)
• Coordinate technical development activities, schedules, and resolution of engineering issues
• Integrate product, process, and lessons‑learned issues into DFMEA documentation
• Coordinate supplier validation testing and review test plans and reports
• Coordinate Ford internal vehicle‑level and subsystem validation testing
• Maintain regular communication with internal Ford teams and external suppliers
• Prepare interim and final project reports and technical presentations
• Release components for production (WERS) and support production issues (SREA, Alerts)
• Manage supplier design data within Ford systems (CAD models, drawings, CAE data)

Required Qualifications:

• 10+ years of experience in mechanical mechanism development, preferably in latching systems, door handles, or exterior mechanisms
• Strong knowledge of engineering plastics and steels, including manufacturing processes such as injection molding, stamping, and casting
• Experience performing and/or leading tolerance analysis studies
• Proficiency with DFMEA and related quality tools, including:
• Boundary/Parameter Diagrams
• Requirements Decomposition Matrix (RDM)
• Interface Matrices
• DVP&R, DOE, SPC, statistical analysis
• Problem‑solving methodologies (5D, 8D, 6‑Panel, Six Sigma)
• Solid understanding of DFM/DFA and GD&T principles
• Experience reviewing and working in CATIA V5/V6
• Familiarity with Teamcenter / ENOVIA for CAD data management
• Strong written and verbal communication skills
• Proficiency with Microsoft Office (Excel, Word, PowerPoint)

Preferred Qualifications:

• Experience with water management and sealing design
• Knowledge of greases and painted plastics
• Familiarity with embedded electronics such as microswitches and small wiring harnesses
• Experience with tolerance analysis tools such as C‑Tol, 3DCS, Enventive, or VSA
• Experience with CAE tools such as ADAMS, Working Model, CATIA FEA, HyperMesh, or similar

Impellam Group and its brands are equal-opportunity employers committed to diversity and inclusion. All qualified applicants will receive consideration without regard to race, color, religion, gender, sexual orientation, pregnancy or maternity, national origin, age, disability, veteran status, or any other factor determined to be unlawful under applicable law. We will ensure that individuals with disabilities are provided reasonable accommodation to participate in the job application, interview process, pre-employment activity, and the performance of crucial job functions.

If you require additional disability considerations, modifications, or adjustments please let us know by contacting View email address on aplitrak.com or fill out this form to request accommodations.