Process Engineer

What to Expect

The Sustaining Process Engineer’s (Sustaining Powertrain Process Engineer) primary responsibilities are to eliminate waste in the manufacturing process, drive long‑term line improvements to yield, cycle time and process capability. In addition, the process engineer will work with a cross‑functional team to develop, introduce, and sustain new model/product/material introductions. They will be responsible for optimizing product flow through the factory through process optimization that may include tool /fixture selection, line layouts, ergonomic study, material presentation, and other relevant factors.

They will interface with design, test, manufacturing, and quality engineering to solve problems, improve manufacturability, and implement continual improvement. They will sustain products with cost reduction and yield improvements. In addition, the Process Engineer will work with quality to compile and evaluate data to determine appropriate limits and variables for process or material specifications.

• Develop expertise in manufacturing processes. Optimize production workstation layouts to enhance product flow, ergonomics, and efficiency while conducting process analysis, DOE, PFMEA, line balancing, and capacity modeling/simulation.
• Participate in the transition of a product from pilot line production and into mass manufacturing. Initiate and drive strategies to rapidly ramp the quality and rate of newly launched production lines to full capacity with a focus on maintaining the highest of safety standards and customer demand throughout the ramp duration.
• Champion continuous improvement projects (CIP) to maximize yield, capacity, and capability. Perform process/quality baseline studies, PFMEAs and root cause analysis to proactively identify and address process/quality issues.
• Responsible for diagnosing issues found during the part manufacturing process and drive corrective action back to source including but not limited to SIE/ SQE, resulting in root cause identification and elimination. Utilize structured problem‑solving techniques such as DMAIC, Ishikawa, Five Why (5W) and Eight Disciplines (8D) to optimize key production outcomes.
• As a process equipment owner, responsible for interfacing with various cross functional teams to drive both short term and long term outcomes – such as production, maintenance, design engineering, quality, manufacturing.
• Synthesize, collate, and analyze data from machine and factory data systems to identify and eliminate bottlenecks, and to reduce operational costs. Use a range of data collection, visualization, and analysis tools to achieve this goal. Enable data‑driven operational and financial decisions through insights into tool and process performance, including integration of factory data systems and use of software such as MySQL, Python, R, JMP, Minitab, Tableau, and Ignition.
• Utilize a range of optimization and experimentation techniques to validate new parts, new processes, and to challenge existing limitations on high volume production lines.
• Monitor and reduce process variation using techniques such as Statistical Process Control (SPC) and Measurement Systems Analysis (MSA). Monitor and audit manufacturing processes to ensure product specifications and standards are achieved. Participate in the development and maintenance of FMEAs and Control Plans. Review and provide disposition to non‑conforming material and perform mechanical and electrical failure analysis on components and assemblies.
• Develop and implement process/quality control strategies, including poka yokes, testing, tooling and inspections.
• Create and maintain Manufacturing Instructions, routings, and associated processes. Develop, mentor and train sustaining technicians, assist in the training of operators as needed. Manage activities for process sustaining technicians to support day‑to‑day coverage of production line, including developing and documenting appropriate rework procedures.

• Bachelor’s Degree in Mechanical, Manufacturing, Industrial, or Chemical Engineering or other Engineering discipline, or equivalent in experience.
• Ability to derive…