Launch Engineer

The Paint Launch Process Coach is responsible for driving the readiness, validation, and stabilization of new paint processes, tools, and vehicle programs during pre-launch and launch phases. This role bridges Manufacturing Engineering, Quality, and Production teams to ensure that new lines, equipment, and process changes are launched safely, on time, and meeting quality targets. The Process Coach leads a team of technicians through trial builds, pilot runs, and ramp-up curves, applying FPS (Ford Production System) principles to identify and resolve issues before they impact full production, while coaching the team on standardized work, problem-solving, and continuous improvement.

• Coordinate daily readiness activities for new model launches, engineering trials, and pilot builds within Paint
• Lead the team during trial runs (PVT, launch curve builds) tracking SQDCME indicators specific to new processes/tools
• Standardize new work instructions (QPS) and train Base Technicians on new processes before ramp-up
• Analyze quality issues found during trial builds using QLS, NGAVS, and root cause tools (5-Why, Fishbone, DMAIC)
• Implement interim containment actions (ICA) and permanent corrective actions (PCA) for launch-related defects
• Model FPS behaviors through start-up, verification, closing, LPR, and standardization during launch phases
• Support escalation of launch issues through DCC/ZCC and Launch Readiness meetings
• Track and update readiness checklists, run-at-rate targets, and launch milestones
• Coordinate with Manufacturing Engineering, Launch Leaders, and suppliers for equipment/tooling validation
• Manage basic personnel administration through PeopleSoft-DROT and ensure team versatility for launch coverage
• Document lessons learned, kaizens, and launch projects in DMAIC/e-Kaizen format for future program reuse

Key Responsibilities

• Launch Readiness Coordination: ensure all processes, tools, and personnel are prepared for new program start-ups
• Team Leadership during Ramp-Up: guide the team through trial builds and volume ramp-up curves, adjusting staffing and standard work as needed
• Root Cause Analysis: identify and resolve new quality/process issues unique to launch conditions before they escalate to mass production
• Cross-functional Coordination: work closely with Manufacturing Engineering, Quality, Launch Leaders, and suppliers to validate new equipment and processes
• Standardization & Training: develop and roll out new QPS/standardized work documents and train technicians ahead of production
• Continuous Improvement: capture launch learnings and drive kaizen activities to shorten future launch curves
• Reporting: track launch KPIs (FTT, run-at-rate, readiness %) and report status in ZCC/DCC and launch-specific forums

Qualifications

• Bachelor's degree completed (Engineering preferred: Industrial, Mechanical, or related)
• 1 year work experience
• English proficiency
• Skills: conflict management, communication, leadership, proactivity, adaptability to fast-changing environments
• Knowledge: Microsoft Office, statistical tools, exposure to launch/new model introduction processes (desirable)

Must Have Skills

• Team leadership and people management under high-pressure/fast-paced launch timelines
• Strong problem-solving skills (root cause analysis, 5-Why, containment/corrective action implementation)
• Knowledge of FPS (Ford Production System) principles and standardized work
• Ability to read and interpret quality data (FTT, defect trends) and translate into action plans
• Effective cross-functional communication (Engineering, Quality, Production, Suppliers)
• Proficiency in Microsoft Office and statistical/quality tools
• Comfortable working with ambiguity and rapidly evolving processes typical of launch environments

Highly Desirable Skills

• Prior exposure to New Model Launch, PVT (Prototype/Pilot Vehicle Team) builds, or run-at-rate events
• Familiarity with Paint process technology (application, sealer, inspection & repair)
• Experience with QLS, NGAVS, FPS, or similar Ford quality/manufacturing systems
• Project management skills (timeline tracking, milestone management)
• Lean/Six Sigma exposure or DMAIC project experience
• Ability to manage supplier/equipment validation activities

Education Preference

Engineering degree (Industrial, Mechanical, Manufacturing, or related fields)

• Deep expertise in New Model Launch processes within a paint/manufacturing environment
• Leadership and coaching skills for managing teams under launch-phase pressure and tight timelines
• Advanced root cause problem-solving applied to non-standard/new processes
• Cross-functional project coordination experience (Engineering, Quality, Production, Suppliers)
• Practical application of FPS and Lean principles in a launch/ramp-up context
• Data-driven decision-making using launch KPIs and readiness metrics
• End-to-end understanding of the vehicle launch cycle, from pilot builds to full production ramp-up

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