Senior Hardware Manufacturing Test Engineer

We are the movers of the world and the makers of the future. We get up every day, roll up our sleeves and build a better world -- together. At Ford, we're all a part of something bigger than ourselves. Are you ready to change the way the world moves?

Ford's Electric Vehicles, Digital and Design (EVDD) team is charged with delivering the company's vision of a fully electric transportation future. EVDD is customer-obsessed, entrepreneurial, and data-driven and is dedicated to delivering industry-leading customer experience for electric vehicle buyers and owners. You'll join an agile team of doers pioneering our EV future by working collaboratively, staying focused on only what matters, and delivering excellence day in and day out. Join us to make positive change by helping build a better world where every person is free to move and pursue their dreams.

In this position...

We are seeking a highly experienced Senior Manufacturing Hardware Test Engineer to lead the architecture, development, and deployment of end‑of‑line (EOL) manufacturing test systems for electronic and electromechanical products. This role owns test strategy from early product development through high‑volume production and drives continuous improvement in test coverage, equipment reliability, and manufacturing yield.

The Senior Engineer is expected to operate with a high degree of autonomy, provide technical leadership across cross‑functional teams, mentor junior engineers, and act as a key contributor in manufacturing readiness reviews and new product introductions (NPI). This role can be based in either our Long Beach, CA or Allen Park, MI offices.

We are seeking a highly experienced Senior Manufacturing Hardware Test Engineer to lead the architecture, development, and deployment of end‑of‑line (EOL) manufacturing test systems for electronic and electromechanical products. This role owns test strategy from early product development through high‑volume production and drives continuous improvement in test coverage, equipment reliability, and manufacturing yield. The Senior Engineer is expected to operate with a high degree of autonomy, provide technical leadership across cross‑functional teams, mentor junior engineers, and act as a key contributor in manufacturing readiness reviews and new product introductions (NPI).

What you'll do...

Lead the design, architecture, and development of robust EOL test systems for complex electronic and electromechanical assemblies, ensuring scalability and reliability for high‑volume manufacturing.

• Own end‑to‑end test strategy including test coverage definition, fault isolation, and diagnostic capability to meet quality, cost, and throughput targets.
• Serve as the technical focal point for test equipment suppliers and internal stakeholders, guiding specifications, design reviews, supplier selection, and acceptance testing.
• Drive installation, commissioning, and validation of test stations on the manufacturing floor, including site readiness, prove‑out, and production handoff.
• Develop and enforce standardized test methodologies, documentation practices, and calibration strategies across manufacturing programs.
• Lead advanced troubleshooting of complex hardware, software, and system‑level test failures, minimizing downtime and improving overall equipment effectiveness (OEE).
• Analyze large‑scale test data to identify systemic issues, reduce false failures, improve yield, and influence product and process design decisions.
• Ensure compliance with safety, regulatory, quality, and industry standards, acting as a subject‑matter expert during audits and reviews.
• Partner closely with Design Engineering, Manufacturing Engineering, Quality, and Operations to ensure products are manufacturable and testable.
• Mentor and technically guide Associate and mid‑level Test Engineers, providing design feedback, best practices, and career development support.
• Support NPI and design‑for‑test (DFT) initiatives, proactively identifying risks and driving corrective actions before production launch.

Travel 50% of the time may be required in this role.

What you'll do...

Lead the design, architecture, and development of robust EOL test systems for complex electronic and electromechanical assemblies, ensuring scalability and reliability for high‑volume manufacturing.

• Own end‑to‑end test strategy including test coverage definition, fault isolation, and diagnostic capability to meet quality, cost, and throughput targets.
• Serve as the technical focal point for test equipment suppliers and internal stakeholders, guiding specifications, design reviews, supplier selection, and acceptance testing.
• Drive installation, commissioning, and validation of test stations on the manufacturing floor, including site readiness, prove‑out, and production handoff.
• Develop and enforce standardized test methodologies, documentation practices, and calibration strategies across manufacturing programs.
• Lead advanced troubleshooting of complex hardware, software, and system‑level test failures, minimizing downtime and improving overall equipment effectiveness (OEE).
• Analyze large‑scale test data to identify systemic issues, reduce false failures, improve yield, and influence product and process design decisions.
• Ensure compliance with safety, regulatory, quality, and industry standards, acting as a subject‑matter expert during audits and reviews.
• Partner closely with Design Engineering, Manufacturing Engineering, Quality, and Operations to ensure products are manufacturable and testable.
• Mentor and technically guide Associate and mid‑level Test Engineers, providing design feedback, best practices, and career development support.
• Support NPI and design‑for‑test (DFT) initiatives, proactively identifying risks and driving corrective actions before production launch.

Travel 50% of the time may be required in this role.