Position Summary:
The Process Engineer plays a critical role in driving continuous improvement, operational excellence, and lean manufacturing practices in a high-volume automotive production environment. This role is responsible for analyzing, designing, and optimizing manufacturing processes to reduce waste, improve efficiency, and ensure product quality while meeting cost and delivery targets. The Process Engineer should provide factory floor coaching/leadership/technical expertise to improve Key Performance Indicators. The Process Engineer should be able to teach problem-solving methods to the plant teams on a day-to-day basis. The Process Engineer should actively support and improve the Plant Quality Management System.

Key Responsibilities:

• Analyze existing production processes and implement Lean methodologies (e.g., 5S, Value Stream Mapping, SMED, Kaizen, Kanban, Standard Work) to eliminate waste and drive continuous improvement.
• Design, implement, and optimize manufacturing processes for new and existing products, ensuring alignment with automotive quality and safety standards (e.g., IATF 16949, ISO 9001).
• Lead cross-functional process improvement projects focused on throughput, OEE, cycle time reduction, and scrap minimization.
• Support launch of new automotive programs by developing robust and efficient process flows, PFMEAs, and control plans.
• Collaborate with Quality, Maintenance, and Production teams to resolve process-related issues and implement root cause corrective actions using tools such as 8D, DMAIC, or A3.
• Drive cost savings initiatives through automation, layout optimization, and best-practice standardization.
• Use statistical methods (SPC, DOE, process capability analysis) to monitor and improve process performance.
• Lead trials, validations, and changeovers to ensure minimal downtime and effective implementation of engineering changes.
• Maintain accurate documentation for all processes, including SOPs, work instructions, and process maps.
• Own and drive improvements in the Quality Management System.
• Act as a Lean champion to train and coach operators and support teams on lean tools and behaviors.

Qualifications:

• Bachelor’s degree in Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, or related field.
• 3+ years of experience in a manufacturing environment, preferably in automotive or high-volume assembly.
• Demonstrated expertise in Lean Manufacturing and Continuous Improvement methodologies.
• Working knowledge of automotive quality systems and standards (e.g., APQP, PPAP, IATF 16949).
• Proficiency in CAD tools (e.g., AutoCAD, SolidWorks), MS Office Suite, and manufacturing analytics tools.
• Strong problem-solving skills and familiarity with Six Sigma or structured problem-solving methods.
• Effective communicator and team collaborator with a hands-on approach and sense of urgency.

Preferred Qualifications:

• Lean Six Sigma Green Belt or Black Belt certification.
• Experience with MES, ERP, or other manufacturing systems.
• Prior experience in launching new automotive programs or tier-1 supplier operations.

• Analyze existing production processes and implement Lean methodologies (e.g., 5S, Value Stream Mapping, SMED, Kaizen, Kanban, Standard Work) to eliminate waste and drive continuous improvement.
• Design, implement, and optimize manufacturing processes for new and existing products, ensuring alignment with automotive quality and safety standards (e.g., IATF 16949, ISO 9001).
• Lead cross-functional process improvement projects focused on throughput, OEE, cycle time reduction, and scrap minimization.
• Support launch of new automotive programs by developing robust and efficient process flows, PFMEAs, and control plans.
• Collaborate with Quality, Maintenance, and Production teams to resolve process-related issues and implement root cause corrective actions using tools such as 8D, DMAIC, or A3.
• Drive cost savings initiatives through automation, layout optimization, and best-practice standardization.
• Use statistical methods (SPC, DOE, process capability analysis) to monitor and improve process performance.
• Lead trials, validations, and changeovers to ensure minimal downtime and effective implementation of engineering changes.
• Maintain accurate documentation for all processes, including SOPs, work instructions, and process maps.
• Own and drive improvements in the Quality Management System.
• Act as a Lean champion to train and coach operators and support teams on lean tools and behaviors