Senior Process Engineer

Warsaw, Indiana - Senior Process Engineer, Seats #1057880

The Senior Process Engineer of Seats Production is responsible for analyzing, designing, and improving manufacturing processes to maximize efficiency, quality, safety, and cost performance. This role applies industrial engineering principles to optimize labor, material flow, equipment utilization, and production systems while supporting new product launches, capacity expansion, and continuous improvement initiatives. Works closely with manufacturing, quality, supply chain, and automation teams to drive data-based decisions and deliver sustainable operational improvements.

• Process Design & Optimization
  • Develop and improve manufacturing processes for efficiency and cost-effectiveness.
  • Conduct time studies, work measurement, and line balancing.
  • Implement lean manufacturing principles (Kaizen, 5S, SMED).
• Layout & Material Flow
  • Design plant layouts, workstation ergonomics, and material flow.
  • Optimize logistics within the plant (kanban systems, material handling).
  • Ensure space utilization and smooth workflow.
• Capacity Planning & Resource Management
  • Analyze production capacity, time study, and forecast requirements.
  • Plan manpower, machines, and tooling for new and existing programs.
  • Support capital investment decisions for equipment.
• Cost Analysis & Continuous Improvement
  • Perform cost analysis for processes and suggest improvements.
  • Drive continuous improvement projects to reduce waste and increase productivity.
  • Monitor KPIs like cycle time, OEE, and scrap rates.
• Quality & Safety Integration
  • Ensure processes comply with quality standards.
  • Integrate ergonomics and safety into process design.
  • Support root cause analysis for process-related defects.
• New Program Support
  • Participate in DFM/A reviews.
  • Support launch readiness by validating process capability.
  • Prepare Process FMEA, work instructions and standard operating procedures.

• 12+ years related automotive manufacturing experience with Bachelor's degree, 8 years with Master's degree, 5 years with PhD or equivalent experience.
• Experience with lean manufacturing, Six Sigma, and ERP systems.
• Automotive OEM experience preferred.
• Experience with Just-In-Time (JIT) manufacturing.

• Proven leadership skills and ability to manage cross-functional teams.
• Strong knowledge of trim line processes and automotive interior components.
• Excellent problem-solving, communication, and organizational skills.
• Proficiency in Microsoft Office and production planning software.

• Manufacturing plant environment.
• Exposure to moving machinery and industrial noise.
• May require shift work (days, nights, weekends).