Process Engineer

1. New Product & Process Development

• Develop and establish manufacturing processes for new products.
• Review product drawings, specifications and process requirements.
• Conduct process feasibility studies and identify manufacturing constraints.
• Support new product introduction (NPI) and pilot production.
• Prepare and validate process flow, work instructions and standard operating procedures.

2. Process Planning & Documentation

• Prepare and maintain Process Flow Diagrams (PFD), PFMEA, Control Plans and SOPs.
• Define process parameters, cycle time, manpower and equipment requirements.
• Develop line layouts and optimize material flow.
• Establish standard work and process control methods.

3. Productivity & Process Improvement

• Drive cycle-time reduction, line balancing and productivity improvement.
• Identify bottlenecks and implement corrective actions.
• Improve OEE, machine utilization and manpower productivity.
• Apply Lean Manufacturing, Kaizen, 5S and other continuous-improvement techniques.
• Reduce process losses, rejection, rework and material wastage.

4. Quality & Problem Solving

• Analyze process-related quality issues using RCA, 5 Why, Fishbone, 8D and CAPA.
• Work closely with Quality, Production, Maintenance and R&D teams to resolve process issues.
• Implement mistake-proofing (Poka-Yoke) wherever applicable.
• Monitor process capability and ensure adherence to defined specifications.
• Support customer complaints and corrective/preventive actions related to manufacturing processes.

5. Production Support

• Provide technical support to production teams for daily process-related issues.
• Monitor process parameters and ensure compliance with standard operating conditions.
• Support trial runs, process validation and mass-production stabilization.
• Train operators and production personnel on revised processes and work instructions.

6. Tooling, Fixture & Equipment

• Coordinate with tooling, maintenance and equipment teams for process requirements.
• Develop specifications for jigs, fixtures, gauges and special-purpose machines.
• Participate in machine commissioning and process validation.
• Identify automation opportunities to improve productivity, quality and safety.

7. Cost & Efficiency Improvement

• Identify opportunities for cost reduction and value engineering.
• Optimize manpower, machine utilization, material consumption and cycle time.
• Support VA/VE initiatives and productivity improvement projects.
• Track savings generated through process improvement activities.

8. Safety & Compliance

• Ensure processes comply with safety standards and company requirements.
• Identify process-related safety risks and implement corrective measures.
• Support risk assessments and safe operating procedures.
• Ensure compliance with applicable automotive quality systems and internal procedures.

Key Skills

• OEE
• Cycle Time
• Line Balance Efficiency
• Productivity
• Process Rejection / PPM
• Rework & Scrap
• Process Capability (Cp/Cpk)
• Kaizen / Cost Reduction
• Downtime
• First Pass Yield (FPY)
• New Product Launch / NPI milestones
• Process Audit Compliance
• Customer Complaint / Quality Closure