Process Engineer

Process Engineer – Automotive Manufacturing Position: Process Engineer Department: Engineering Industry: Automotive Manufacturing / Tier 1 or Tier 2 Supplier Reports To: Engineering Manager or Plant Manager Employment Type: Full-Time Job Summary The Process Engineer is responsible for developing, optimizing, and maintaining manufacturing processes to improve production efficiency, product quality, safety, and cost effectiveness within an automotive manufacturing facility. This role works closely with production, quality, maintenance, and engineering teams to troubleshoot process issues, implement continuous improvement initiatives, and ensure manufacturing operations meet customer specifications and industry standards. The ideal candidate will have hands-on experience in automotive manufacturing, strong problem-solving skills, and a background in process optimization, root cause analysis, and lean manufacturing principles.

Key Responsibilities

Manufacturing Process Development & Improvement

• Develop, evaluate, and optimize manufacturing processes to improve productivity, efficiency, and product quality.
• Analyze production workflows, cycle times, downtime, scrap, and bottlenecks to identify improvement opportunities.
• Establish and maintain standardized work instructions, process parameters, and manufacturing documentation.
• Support new product launches, process development, equipment installations, and production line commissioning.
• Implement process improvements to reduce manufacturing costs, waste, and cycle times.
• Ensure manufacturing processes meet customer requirements, engineering specifications, and production targets.

Troubleshooting & Root Cause Analysis

• Investigate production problems, process deviations, equipment issues, and quality defects.
• Conduct root cause analysis using methods such as 5 Why, fishbone diagrams, and corrective action processes.
• Collaborate with production, maintenance, and quality teams to implement permanent corrective and preventive actions.
• Monitor process performance and establish controls to prevent recurring issues.
• Provide technical support to production teams during equipment failures, process changes, and manufacturing disruptions.

Quality & Continuous Improvement

• Partner with Quality Engineering to address customer complaints, internal defects, scrap, and rework.
• Support PFMEA, Control Plans, Process Flow Diagrams, work instructions, and other manufacturing documentation.
• Participate in APQP, PPAP, process validation, capability studies, and production readiness activities.
• Apply lean manufacturing principles, including 5S, Kaizen, standard work, and waste reduction.
• Monitor key performance indicators, including OEE, cycle time, scrap rates, downtime, and throughput.
• Support compliance with IATF 16949, ISO 9001, and applicable customer-specific requirements.

Equipment, Tooling & Automation

• Evaluate manufacturing equipment, tooling, fixtures, and production layouts for process improvements.
• Support the installation, startup, and validation of new equipment and manufacturing systems.
• Work with maintenance and automation personnel to improve equipment reliability and process repeatability.
• Assist with troubleshooting automated production lines, robotics, PLC-controlled equipment, and other manufacturing technologies as applicable.
• Develop process parameters and operating standards to ensure consistent production performance.

Cross-Functional Collaboration

• Work closely with Production, Quality, Maintenance, Tooling, and Supply Chain teams to resolve manufacturing challenges.
• Provide technical guidance and training to production personnel on process changes and standardized procedures.
• Support engineering changes, product launches, equipment upgrades, and capacity improvement projects.
• Coordinate with suppliers and equipment vendors on process development, tooling, and technical issues as needed.
• Prepare engineering reports, process documentation, and improvement recommendations for management.

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or a related technical discipline preferred. Will consider experience in lieu of a degree.
• Minimum of 3–5 years of process engineering experience in automotive or industrial manufacturing.
• Strong understanding of manufacturing processes, production systems, and continuous improvement methodologies.
• Experience with root cause analysis, corrective actions, process optimization, and troubleshooting.
• Knowledge of PFMEA, Control Plans, APQP, PPAP, and process validation.
• Familiarity with lean manufacturing, Six Sigma, 5S, and Kaizen principles.
• Ability to analyze production data, identify trends, and develop effective solutions.
• Strong communication, project management, and problem-solving skills.
• Proficiency with Microsoft Office and manufacturing or quality documentation systems.