Description

Objective

Provide specialized services to optimize the manufacturing processes for a prototype gear set, with the goals of improving efficiency, reducing production variability, enhancing manufacturability, and ensuring full compliance with Client's quality, performance, and durability standards.

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Scope of Services

1. Process Analysis & Benchmarking

•\tReview current gear manufacturing workflows, equipment capabilities, and process parameters.

•\tIdentify inefficiencies, bottlenecks, and sources of dimensional or surface-finish variation.

•\tBenchmark against Ford specifications, GD&T requirements, and applicable client standards (e.g., material, heat treatment, cleanliness, testing).

2. Gear DFM/DFX Review

•\tAssess prototype gear geometry for manufacturability, tooling constraints, and tolerance stack-up.

•\tRecommend adjustments to improve production robustness without compromising performance.

•\tEvaluate impacts on NVH, fatigue life, and load-carrying performance.

3. Manufacturing Process Optimization

•\tOptimize key processes such as:

o\tGear cutting (hobbing, Milling)

o\tHeat treatment (carburizing, quench parameters, distortion control)

o\tGrinding, honing, superfinishing

o\tQuality inspection workflows

•\tDevelop improved work instructions, fixture designs, and process controls.

•\tImplement statistical process control (SPC) and capability studies (Cp/Cpk).

4. Material & Heat Treatment Compliance

•\tVerify materials and heat treatment meet Client standards (e.g., microstructure, hardness profile, case depth).

•\tProvide corrective actions or alternative process plans for issues such as distortion, cracking, or surface integrity.

5. Quality & Metrology Validation

•\tConduct detailed gear metrology including involute profile, lead, pitch, runout, surface roughness, and hardness mapping.

•\tEnsure compliance with Client's dimensional, functional, and performance requirements for prototype gears.

•\tGenerate PPAP-ready documentation if required for later phases.

6. Efficiency Improvements & Cost Reduction

•\tIdentify opportunities for cycle time reduction, improved tool life, and reduced scrap rates.

•\tRecommend automation or fixture upgrades were beneficial.

•\tConduct ROI analysis for proposed improvements.

7. Reporting & Deliverables

•\tProcess capability reports (Cp, Cpk)

•\tUpdated process flow diagrams & PFMEA

•\tCorrective action recommendations

•\tMetrology and testing reports

•\tFinal summary of improvements achieved and compliance verification

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Expected Outcomes

•\tImproved consistency and repeatability in prototype gear manufacturing

•\tReduced lead times and manufacturing costs

•\tHigher confidence that gears meet Ford’s durability, NVH, and performance requirements

•\tFull alignment with Client's standards and quality expectations

Job Type & Location

This is a Contract position based out of Sterling Heights, MI.

Pay and Benefits

The pay range for this position is $67.00 - $67.00/hr.

Eligibility requirements apply to some benefits and may depend on your job\n classification and length of employment. Benefits are subject to change and may be\n subject to specific elections, plan, or program terms. If eligible, the benefits\n available for this temporary role may include the following:\n\n • Medical, dental & vision\n • Critical Illness, Accident, and Hospital\n • 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available\n • Life Insurance (Voluntary Life & AD&D for the employee and dependents)\n • Short and long-term disability\n • Health Spending Account (HSA)\n • Transportation benefits\n • Employee Assistance Program\n • Time Off/Leave (PTO, Vacation or Sick Leave)

Workplace Type

This is a fully onsite position in Sterling Heights,MI.

Application Deadline

This position is anticipated to close on Dec 26, 2025.

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\n About Aerotek:\n\n

We know that finding work is hard, and finding meaningful work is harder. Aerotek connects 180,000+ light industrial and skilled trades workers with 14,000+ employers each year, helping our workers navigate an evolving labor market and find jobs that meets their goals, skills and interests. Since 1983, we have provided a variety of career opportunities across North American industry – from short-term assignments at Fortune 500 companies where you can build your skills, to long-term opportunities where you can play a vital role solving for companies’ construction, manufacturing and maintenance challenges. Our 1,500+ experienced recruiters across 250+ offices work relentlessly to put our workforce in a position to thrive. Let us rise to meet your challenges and put our people-are everything spirit to the test as your career continues to grow.

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Aerotek offers weekly pay, employee benefits including medical, dental & vision, life insurance, health advocacy and employee assistance programs, a 401(k) plan, and employee discounts.

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The company is an equal opportunity employer and will consider all applications without regards to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

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