Process Engineer

Key Responsibilities

• Design, 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.
• 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: 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.