Process Engineer, General Assembly

Position Overview:
The Process Engineer is responsible for developing, validating, and continuously improving manufacturing processes to ensure they are safe, efficient, and capable of meeting quality and throughput targets. This role supports new product introductions, process validation, tooling readiness, and day-to-day production activities. The Process Engineer plays a key role in driving operational excellence, resolving production issues, and ensuring robust, scalable processes across the manufacturing line.

Key Responsibilities:
o Process Development & Validation:

• Process Design — Develop and optimize manufacturing processes, ensuring alignment with safety, quality, and ergonomic standards.

• Process Validation — Execute validation activities including trial builds, capability studies, and process readiness checks.

• Documentation Management — Create and maintain Standard Work, Control Plans, PFMEAs, Work Instructions, and Process Flow Diagrams.

• Tooling & Equipment Readiness — Support tooling validation, equipment buy-off, and readiness for production launch.

o Quality & Performance Monitoring:

• KPI Tracking — Monitor process KPIs such as FTQ, cycle time, scrap, and rework rates; escalate deviations.

• Root Cause Analysis — Work with Quality and Production teams to identify root causes and implement corrective actions.

• Process Stability — Support ramp-up and launch activities to ensure stable and capable production processes.

o Process Engineering Execution:

• Ergonomics & Safety — Conduct ergonomic assessments and ensure compliance with safety standards.

• Torque & Fastening — Support torque studies, fastening validation, and joint integrity checks where applicable.

• Error-Proofing — Implement Poka-Yoke solutions, visual management, and process control systems.

• Continuous Documentation Updates — Maintain PFMEAs, Control Plans, and Standard Work as processes evolve.

o Problem Solving & Continuous Improvement:

• Structured Problem Solving — Use 5-Why, Fishbone, 8D, and other structured tools to resolve production issues.

• Continuous Improvement — Support Kaizen events, waste reduction, and process optimization initiatives.

• Lessons Learned — Capture and apply lessons learned to strengthen process robustness and prevent recurrence.

o Cross-Functional Collaboration:

• Cross-Functional Alignment — Work closely with Product Engineering, Manufacturing Engineering, Quality, Logistics, Maintenance, and Operations.

• DFM Support — Participate in DFM reviews and provide feedback on manufacturability and process requirements.

• Launch Readiness — Support launch readiness reviews and engineering change implementation.

Skills:
o Technical Skills:

• Manufacturing Process Knowledge — Understanding of assembly processes, tooling, and production systems.

• PFMEA & Control Plans — Working knowledge of PFMEA, Control Plans, and process audits.

• MES & Tools — Experience with MES systems, torque tools, and basic CAD/BI tools.

• Material Flow — Understanding of material flow, kitting, and line balancing concepts.

o Personal Skills: • Analytical Thinking — Strong analytical and problem-solving skills.

• Communication — Effective communication and teamwork across functions.

• Attention to Detail — High attention to detail and strong ownership mindset.

• Adaptability — Ability to work effectively in a fast-paced production environment.

Minimum Qualifications:
o Education:

• Bachelor’s degree in industrial, Mechanical, Electrical, Automation Engineering, or related field.

o Experience:

• 3–6 years of experience in automotive manufacturing or process engineering.

• Experience supporting process validation, launches, or production environments.

• Hands-on experience with problem-solving methodologies and process control.

• Understanding of production systems and high-volume manufacturing operations.

o Specific Requirements:

• Flexibility to support off-shifts and weekend activities during launch phases.

• Experience in automotive or high-volume manufacturing environments preferred.