Sr. Process Engineer

The Senior Process Engineer is responsible for leading the design, development, implementation, validation, and continuous improvement of manufacturing processes that deliver world-class safety, quality, productivity, and cost performance in a high-volume automotive manufacturing environment. This role serves as the technical leader for manufacturing processes, providing direction to cross-functional teams while supporting new product launches, automation initiatives, robotics integration, PLC-controlled equipment, and advanced manufacturing technologies.

The Senior Process Engineer partners closely with Production, Quality, Maintenance, Supply Chain, and Product Engineering to develop robust manufacturing systems that meet IATF 16949, VDA 6.3, customer-specific requirements, and operational excellence objectives. This position is expected to mentor engineers and technicians, lead complex manufacturing projects, drive process standardization, and champion continuous improvement initiatives throughout the product lifecycle.

Key Responsibilities

• Serve as the technical leader for manufacturing processes, providing guidance and direction to engineers, technicians, and cross-functional teams.

• Lead multidisciplinary teams during new product launches, automation projects, and major manufacturing improvements.

• Mentor and develop Process Engineers, and Engineering Technicians through coaching and knowledge sharing.

• Drive a culture of continuous improvement, accountability, and operational excellence across manufacturing operations.

• Develop, implement, and optimize manufacturing processes

• Analyze production data and implement corrective actions

• Support APQP deliverables (Process Flow, PFMEA, Control Plan)

• Maintain process documentation (work instructions, SOPs)

• Collaborate with Quality, Production, and Maintenance teams

• Support new equipment installation and process improvements

• Monitor process KPIs (scrap, yield, cycle time)

• Participate in audits and compliance activities

• Lead automation projects including specification, design review, implementation, commissioning, and validation of manufacturing equipment.

• Support integration of PLCs, robotics, machine vision, sensors, poka-yoke systems, and Industry 4.0 technologies. Collaborate with automation suppliers and system integrators to ensure successful project execution.

• Develop manufacturing strategies that improve safety, quality, productivity, and profitability.

• Lead process design reviews and manufacturability (DFM/DFA) assessments for new product introductions.

• Establish and maintain standardized manufacturing methods across production lines.

• Lead process capability studies (Cp/Cpk), DOE activities, and statistical analysis to optimize manufacturing performance.

Qualifications

• Bachelor’s degree in mechanical, Industrial, or Manufacturing Engineering

• Knowledge in PLC (Allen Bradley / Keyence)

• Knowledge in Keyence Cameras and Scanner systems

• Knowledge of 6 Axis Kuka Robots and AI vision systems is preferred

• 7+ years of experience in automotive manufacturing or advanced manufacturing engineering

• Knowledge of Lean, Six Sigma, and continuous improvement methodologies

• Experience with APQP, PFMEA, Control Plans, SPC, and MSA

• Strong problem-solving and analytical skills

• Proven experience leading manufacturing improvement projects.

• Experience leading cross-functional teams.

• Experience managing automation suppliers and equipment integrators.

• Experience with capital equipment procurement and implementation.

• Strong knowledge in balancing concepts and functionality (static, dynamic) is a plus

• Leads by Example

• Develops Others through coaching and mentoring.

• Influences without authority.

• Makes sound technical decisions under pressure.

• Builds high-performing cross-functional teams.

• Drives accountability and execution.

• Champions innovation and continuous improvement.

• String communicates with all organizational levels.

Physical Demands

• Ability to stand, walk, and move around the manufacturing floor for extended periods

• Occasional lifting up to 25 lbs

• Manual dexterity for tools and equipment

• Ability to wear PPE (safety glasses, gloves, steel-toe boots)

Safety Requirements

• Follow all EHS and OSHA safety protocols

• Participate in safety training and emergency drills

• Adhere to Lockout/Tagout (LOTO) procedures

• Maintain safe and hazard-free work environment

Individual Contributor Competencies

Collaborates: Works effectively across functions to achieve common goals.  Build strong relationships with stakeholders

Nimble Learning: Quickly adapts to change and learns new skills.  Apply new knowledge to improve performance

Thinks Like an Owner: Takes accountability for results and process performance.  Make decisions with cost, quality, and efficiency in mind