Manufacturing Process Development Engineer

Manufacturing Process Development Engineer

Kelly® Engineering is seeking a Manufacturing Process Development Engineer for a direct-hire position with a global automotive component manufacturer in Auburn Hills, MI.

Overview Our client is a global automotive supplier that manufactures injection-molded components and is expanding into higher-value products incorporating secondary operations, automated assembly, functional testing, and integrated plastic, metallic, mechanical, and electronic content.

This position will develop the manufacturing strategy for new programs from quotation through production launch. The engineer will define complete process flows, establish equipment and automation requirements, coordinate with equipment suppliers, and ensure new assembly processes are efficient, repeatable, cost-effective, and production-ready.

Responsibilities

• Support new programs from quotation through equipment implementation, validation, launch, and production handoff.
• Develop end-to-end process flows covering component receipt, secondary operations, automated assembly, testing, material movement, and finished-product delivery.
• Evaluate manufacturing concepts during quoting by estimating process steps, cycle times, labor, capacity, tooling, equipment, and production costs.
• Define specifications for automated assembly equipment, workstations, fixtures, material-handling systems, process controls, and end-of-line testing.
• Develop processes for assemblies incorporating plastic and metallic parts, springs, gaskets, inserts, connectors, wiring, and other mechanical or electronic content.
• Apply automation concepts such as robotic handling, pick-and-place, component insertion, error-proofing, inspection, and functional testing.
• Partner with equipment integrators and suppliers to review concepts, resolve technical issues, confirm requirements, and support equipment acceptance and installation.
• Establish process controls, quality checks, functionality tests, and validation plans.
• Collaborate with product engineering, operations, quality, maintenance, purchasing, program management, and suppliers.
• Support equipment trials, process validation, production ramp-up, and process refinement.
• Travel to manufacturing and supplier sites as needed, including possible domestic and international travel.

Qualifications

• Bachelor's degree in Manufacturing, Mechanical, Industrial, Automation, or a related engineering discipline; equivalent relevant experience may be considered.
• Approximately five or more years of manufacturing or process engineering experience involving automated assembly, secondary operations, equipment development, or new-product launches.
• Experience defining complete manufacturing processes for complex, multicomponent products or assemblies.
• Ability to translate product requirements into process concepts, equipment specifications, cycle-time assumptions, and manufacturing cost estimates.
• Knowledge of automated assembly, robotics, pick-and-place equipment, fixtures, sensors, inspection, error-proofing, and end-of-line testing. Direct robot or PLC programming is not required.
• Experience working with automation integrators, machine builders, tooling suppliers, or manufacturing-equipment vendors.
• Strong project ownership, problem-solving, communication, and cross-functional collaboration skills.
• Automotive manufacturing experience—particularly involving HVAC, powertrain, transmission, interior, under-hood, or electromechanical assemblies—is preferred.
• Experience integrating plastic, metallic, mechanical, electrical, or electronic components through automated assembly operations is preferred.
• Familiarity with injection molding and automotive launch or quality tools such as APQP, PFMEA, control plans, capability studies, and production validation is beneficial.