Senior Process Engineer

Senior Process Engineer Job Summary As a Senior Process Engineer, you will be responsible for the full scope of projects, including development, planning, execution and implementation of manufacturing processes for new and existing production lines. You will lead process improvement initiatives, analysing and recommending the most effective solutions while ensuring compliance with industry standards and customer specifications.

Responsibility

Design, improve and maintain machining processes to meet and exceed customer requirements while ensuring all documentation is kept current and accurate.

Plan and coordinate implementation of assigned projects in preparation for production.

Coordinate efforts of assigned Project/Process Engineer(s), Quality Engineer(s) and Manufacturing Engineer(s), and other personnel as required to complete job assignments in accordance with established deadlines.

Act as primary customer liaison to ensure customer inquiries and requirements are addressed.

Track all costs associated with the program, including material and processing costs, tooling, gauges and customer‑owned tooling for cost recovery, where applicable.

Lead Customer Focus Team, Advanced Product Quality Planning (APQP), FMEA and Cost Attack Team (CAT) activities and report program status at regular frequencies to customers, suppliers, customer focus teams and management.

Ensure PFMEAs are conducted at each stage of program to reduce probability of errors.

Select, design and purchase tools and fixtures as required.

Support gauge design, acquisition and purchasing in coordination with the Quality department.

Identify and coordinate all required subcontracted work to complete the process. Ensure all sub‑contracted purchases (material/machines/fixtures) are completed with all applicable documentation (RFQ/quote covering specific requirements, performance, capabilities, capacities, run‑off/qualification, and warranties).

Ensure PSRs are conducted and action items are completed prior to start of production.

Ensure all continuous improvement and H&S improvements are completed.

Complete machine run‑offs and acceptance as per company procedures.

Conduct, improve and maintain time studies for each process.

Prepare and update all process and operator work instructions for assigned customers to ensure accuracy and conformance to actual procedures.

Ensure compliance with current quality and health and safety standards.

Ensure all processes meet required takt time.

Assist in preparation of quotations for engineering changes, new work or additional order volumes.

Lead continuous improvement activities.

Aid in troubleshooting and root cause analysis of machine faults.

Participate in effective problem resolution through the Corrective Action Process.

Academic/Educational Requirements

Bachelor’s degree in Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, or related field.

8–10 years of experience in process engineering within an automotive parts manufacturing environment.

Required Skills/Experience

Advanced proficiency in all applicable software applications (Microsoft Office, including Project, AutoCAD, SolidWorks).

Demonstrated knowledge of manufacturing processes, advanced machining and tooling.

Able to communicate requirements clearly in all formats (written, verbal, drawing formats).

Knowledge of blueprint reading, GD&T, CMM reports and various gauging measurements.

Experience using specialized equipment and techniques to take precise measurements.

Ability to determine materials and equipment to use for projects and apply the appropriate codes and standards.

Experience in contacting suppliers to verify product availability and specification and negotiate timely deliveries.

Experience as main customer contact during product launches.

Demonstrated leadership abilities/educational background.

Proven track record in process optimisation and implementing Lean Manufacturing and Six Sigma methodologies.

Knowledge of Quality Management Systems (ISO 9001, IATF 16949) and automotive industry standards.

Experience with automation and robotics in automotive manufacturing.

Familiarity with ERP and MES systems.

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