Assembly Process Engineer

Key Responsibilities

• Process Development and Optimization
• Design and Implement: Develop, document, and standardize optimal assembly process parameters (e.g., cycle times, torque specifications, press-fit forces, and sequencing) for all stages of the production line.
• System Upgrades: Lead technical efforts for the renovation and integration of new assembly equipment, such as robotic workstations, conveyor systems, and automated fastening mechanisms.
• Automation: Optimize the performance of advanced assembly technology, including multi-axis robotic arms and vision-guided systems, to maximize throughput and minimize manual intervention.
• Line Balancing: Expertly manage and optimize the multi-stage assembly flow, focusing on Lean Manufacturing principles to ensure smooth hand-offs between workstations and eliminate bottlenecks.
• Workstation Ergonomics:
• Track and control the physical layout of workstations (e.g., bin placement, tool reach, lighting) and environmental factors to ensure operator safety and efficiency.
• Support the transition and qualification of new assembly fixtures and "poka-yoke" (error-proofing) systems across different plants.
• Quality, Audit, and Troubleshooting
• Failure Analysis: Actively troubleshoot and implement corrective actions for assembly defects (e.g., misalignment, fastening failures, cosmetic damage, or functional non-conformance).
• Tolerance Management: Closely monitor and manage component tolerances and fitment (e.g., interference fits, gap and flushness) to ensure parts meet material specifications and investigate deviations.
• Testing: Conduct and oversee rigorous performance testing, including End-of-Line (EOL) functional tests and leak testing for conditional and final product approvals.
• Documentation: Create and maintain detailed Standard Operating Procedures (SOPs), Process Failure Mode and Effects Analysis (PFMEA), and technical audit reports for all assembly operations.

Required Qualifications

• Education: Bachelor’s degree in Mechanical Engineering, Industrial Engineering, or a related field.
• Experience: 5+ years of experience as a Process Engineer, Manufacturing Engineer, or Assembly Engineer in a high-volume industrial environment.
• Technical Expertise:
• Demonstrated expertise in mechanical assembly, fastening technologies, and material handling systems.
• Strong knowledge of automated assembly equipment, PLC logic, and robotic integration.
• Experience with Design for Manufacturing (DFM) and Design for Assembly (DFA) principles.
• Core Competencies:
• Excellent analytical and problem-solving skills (DOE, Root Cause Analysis, 8D).
• Proficiency in project management, including managing vendors and cross-functional teams to deliver capital projects on time and within budget.
• Strong communication skills to provide technical guidance and training to production staff and technicians.