Manufacturing Process Engineer

Job Title:

Manufacturing Process Engineer

This role supports manufacturing process engineering for axle carrier machining operations, with a strong focus on continuous improvement in safety, quality, and productivity. The Manufacturing Process Engineer applies engineering principles and analytical techniques to establish, optimize, and sustain robust manufacturing processes and products within an automotive machining environment. This position plays a key role in resolving machining-related issues, driving variability reduction, and implementing lean manufacturing best practices while ensuring compliance with plant, corporate, governmental, environmental, and ISO standards.

Responsibilities

* Support manufacturing process engineering activities for axle carrier machining operations within an automotive manufacturing environment.

* Drive continuous improvement initiatives in safety, quality, and productivity across the carrier machining area.

* Apply engineering principles and analytical techniques to establish, validate, and continuously improve manufacturing processes and products.

* Develop and execute action plans to investigate, prioritize, and address quality concerns on internal processes and supplier processes.

* Verify the effectiveness of corrective actions on internal and supplier processes to ensure sustained quality improvements.

* Lead and conduct process audits to ensure process discipline aligns with Powertrain Operations guidelines and plant standards.

* Conduct job ergonomic evaluations and implement corrective actions to improve ergonomics and reduce risk for production personnel.

* Analyze axle carrier inventory root causes and lead mapping and corrective actions to reduce carrier rejects and scrap.

* Create clear and detailed process sheets and instruction sheets that support quality methods and standardized work processes.

* Deliver capable processes and tooling for carrier machining operations, ensuring repeatable and stable production performance.

* Take a lead role in resolving machining-related concerns, including troubleshooting issues with powertrain components such as gears, axles, and carriers.

* Lead variability reduction initiatives to improve process capability and reduce defects and process variation.

* Champion lean manufacturing initiatives and best practices, including the use of lean tools such as 5S, Kanban, Poka-yoke, and Value Stream Mapping.

* Ensure compliance with plant policies, corporate standards, governmental regulations, and environmental requirements.

* Support ISO compliance activities, including participation in internal ISO audits and ongoing adherence to ISO standards.

* Support continuous improvement projects in the carrier machining area to enhance throughput, safety, and product quality.

* Identify throughput constraints in machining and related processes, and drive root cause analysis and improvements to increase capacity and flow.

* Utilize structured problem-solving methodologies such as 8D, 5

Why, DMAIC, and DMADV (DFSS) to address process and quality issues.

* Apply TQM principles, PPAP processes, and design of experiments (DOEs) to validate and optimize processes and new product introductions.

* Use visual factory management techniques to improve communication, transparency, and performance tracking on the shop floor.

* Collaborate with cross-functional launch team members to support successful product and process launches from start to finish.

Essential Skills

* 3+ years of experience in automotive manufacturing working in a facility that manufactures metal parts through machining, such as powertrain components, axles, differentials, and axle carriers.

* Hands-on experience in manufacturing engineering and process engineering within a machining environment.

* Demonstrated experience with machining operations for powertrain components, including gears, axles, and carriers.

* Experience supporting or leading a product or process launch from start to finish in a manufacturing environment.

* Strong knowledge of manufacturing processes, including process development, optimization, and control.

* Effective oral and written communication skills, with the ability to clearly document processes and present findings.

* Proficiency in lean manufacturing concepts and tools, including 5S, Kanban, Poka-yoke, and Value Stream Mapping.

* Experience applying Six Sigma methodologies and structured problem-solving techniques.

* Proficiency with 8D and 5

Why corrective action and problem-solving methods.

* Experience using DMAIC and DMADV (Design for Six Sigma) project methodologies.

* Knowledge and experience with Total Quality Management (TQM) principles.

* Experience with Production Part Approval Process (PPAP) requirements and documentation.

* Experience designing and executing Design of Experiments (DOEs) to optimize processes.

* Familiarity with visual factory management practices to support performance tracking and communication.

* Ergonomic analysis knowledge and experience, including conducting…