Product Development Engineer - Exterior Lighting Vision Systems

We made history and now we work to transform the future - for our customers, our communities and our families. You’ll see your work on the road every day, helping people move freely and pursue their dreams. At Ford, you can build more than vehicles. Come build what matters. In this position… The Exterior Lighting Engineer is a multi-disciplinary technical authority responsible for the integrity, evolution, and in-house design ownership of lighting systems. As the department shifts toward Build-to-Print (BTP) models and AI-driven engineering, this role is the primary driver of Ford’s internal technical foundation. This position bridges the gap between mechanical, electrical, software, and optical engineering. Whether focused on advanced development or application execution, the engineer is the primary lead in ensuring that lighting technologies are not only robust and manufacturable but also developed using the most advanced digital transformation tools available. Responsibilities: Technical Standards, Requirements, and AI Driven Innovation This position is responsible for the “DNA” of our lighting products. Unlike generalist roles, this engineer must master:

• Build-to-Print (BTP) Execution: Leading the transition from supplier-led designs to Ford-owned “Build-to-Print” applications. This includes developing detailed internal CAD, optical models, and technical data packages to ensure full ownership of the design and manufacturing specifications.
• AI-Driven Development & Efficiency: Utilizing and developing Artificial Intelligence to automate administrative and data-heavy tasks, enabling more time for high-value In-House-Design. Leverage Artificial Intelligence Generative design tools to optimize optical performance, thermal management, and structural integrity. This role is critical for implementing automated workflows that accelerate the cycle from concept to validation.
• Requirements & Design Rules: Defining and maintaining the technical specifications and global design rules that govern all lighting programs to ensure consistency and performance.
• In-House Technology Development: Driving the research and development of next-generation lighting technologies (e.g., advanced LEDs, ADB/Matrix, laser, or OLED systems) to maintain a competitive advantage.
• Regulatory Leadership: Serving as the technical lead for global compliance (FMVSS 108, ECE, etc.), ensuring that both current applications and future technologies meet stringent legal and safety requirements.

Quality Engineering and Risk Mitigation (FMA/FMEA) are essential to our technical risk management framework. This role is critical for:

• Failure Mode Avoidance (FMA): Leading the proactive identification of risks through the development and ownership of DFMEA (Design Failure Mode and Effects Analysis) and supporting PFMEA (Process Failure Mode and Effects Analysis) to ensure flawless manufacturing.
• Root Cause Analysis: Serving as the lead investigator for complex system failures. This requires physical teardowns, forensic analysis of field returns, and the engineering of technical countermeasures to prevent recurrence (PRAs).
• Quality & Warranty Stewardship: Owning the technical “health” of the commodity. This engineer directly impacts quality metrics and warranty spend by ensuring that design-level flaws are engineered out before they reach the customer.

Financial & Program Integrity (TVM and Delivery) Exterior lighting is one of the highest-value commodities on the vehicle. This role is essential for:

• Team Value Management (TVM): Identifying and executing technical cost-reduction strategies through BTP efficiencies, without compromising quality or regulatory compliance.
• Cross-Functional Integration: Leading the negotiation between Studio’s aesthetic vision, manufacturing feasibility, and purchasing targets. Without this technical lead, the balance between “styling” and “functionality” is lost, leading to costly late-stage engineering changes.
• Pre-Program Leadership: Acting as the technical authority during early-stage feasibility (Pre-PS) to ensure that aesthetic vision and engineering requirements are aligned before program kick-off.

What you’ll do…

• Collaborate with cross functional teams to deliver a robust system at vehicle level, ensuring all system interfaces of Lighting components are evaluated and validated.
• Create and present technical presentations for peer and management reviews.
• Perform and/or review & sign off technical analyses of component/system functional and packaging studies such as: dimensional stackups (GD&T layouts), CAE’s, dynamic calculations and simulations, etc.
• Actively participate in the Technical Design Reviews.
• Review and sign-off CAD in Teamcenter
• Develop Lighting System documents including DFMEAs, SCCAF, Boundary Diagrams, P-Diagrams, & DVP&Rs
• Lead design reviews based on Failure Mode Avoidance.
• Develop ESOW (Engineering Statement of Work), EC (Engineering concepts) and participate in the sourcing Process (SOBA, ED&T review, piece cost and tooling cost review.
• Identify validation, durability and functional tests required as per SDS & ES. (DVP / FEDE)
• Address issues with root cause analysis (8Ds, 3x5Why) and permanent corrective actions implementation.
• Apply knowledge of six sigma principles.
• Collaborate with STA with technical assistance through the Supplier Engagement Process.
• Deliver by applying the One Ford Behaviors.
• Travel to supplier manufacturing and testing sites when required.
• Travel to North America plants when required.

• Bachelor’s degree or higher in mechanical engineering or a related field.
• 5+ years of experience in design, development, or launch of automotive lighting or similar components
• CAD Capable (such as CATIA, 3DX, Teamcenter) & familiarity with CAE tools and software.
• Benchmarking experience
• Integration and developing CAD studies to support and drive design improvements.
• Demonstrated ability to manage multiple issues effectively and efficiently
• Demonstrated ability to show initiative and prioritize workload.
• Ability to travel domestical and international.
• Proficient in MS Office apps such as Excel, Word, Power Point MS Teams, and MS Azure SharePoint.

Even better, you may have…

• Master’s of Science in Engineering (Mechanical preferred).
• 7+ years of experience
• Experience in design and release of Exterior Lighting
• Software literacy and mechatronics experience.
• Strong understanding of statistical analysis.
• 8D and 5Why corrective action and problem-solving skills.
• Experience with DFMEA’s, PFMEA’s, and SCCAF’s
• Detailed understanding of materials, manufacturing technologies, and GD&T
• Ability to work in a fluid environment when overall vehicle targets, size, appearance, and manufacturing location are not always known.
• Ability to solve complex system issues and deal with a variety of concrete variables in situations where only limited standardization exists.
• Effective oral and written communication skills.
• Ability to adapt your role to a variety of applications and issues as required., + $100,000-150,000 per year Job Category: PD Operations and Quality Degree Level: Bachelor’s Degree or equivalent Job Description: Do you have what it takes to make smart vehicles for a smart world? Joi…

You may not check every box, or your experience may look a little different from what we’ve outlined, but if you think you can bring value to Ford Motor Company, we encourage you to apply! As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder…or all of the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

This position is a salary grade 5 through grade 8. Potential salaries can range from $68,300-$192,900. Final determination of salary grade will be based on candidate’s skills and experience, and base salary will be set within the applicable range according to job scope, responsibility and competitive market value.

• $68,300-192,900 per year We made history and now we work to transform the future - for our customers, our communities and our families. You’ll see your work on the road every day, helping people move freel…