Process Engineer

Job Description: Process Engineer

Location: Ahmedabad, Gujarat
Qualification: B.E. in Mechanical Engineering
Experience: 5 to 7 years
Preferred Industry: Automotive / Automobile Manufacturing

1. Required Skills and Experience

• Bachelors degree in Mechanical Engineering with 5–7 years of experience in Process Engineering, preferably in the automotive industry.
• Good understanding of manufacturing processes, process planning, production feasibility, and quality requirements.
• Hands-on experience in PFMEA, DFMEA, MBOM, EBOM, SAP mapping, PPAP, and process validation.
• Experience in tooling, equipment, gauges, supplier coordination, and production line or cell layout planning.
• Strong communication skills in English and proficiency in the local language.

2. Key Responsibilities

A. Process Planning and Engineering

• Initiate and develop Process Failure Mode and Effects Analysis (PFMEA) based on Generic PFMEA and Design Failure Mode and Effects Analysis (DFMEA) inputs.
• Understand the Engineering Bill of Materials (EBOM) and prepare the Manufacturing Bill of Materials (MBOM), ensuring accurate mapping in SAP.
• Review prototype build feasibility and define quality control checkpoints.
• Develop and implement process validation plans in agreement with the customer.
• Define gauge specifications and establish requirements for tooling and manufacturing equipment.
• Plan and develop plant layouts, manufacturing cells, and production processes.
• Prepare and maintain production process instructions and relevant engineering documentation.

B. Supplier, Tooling, and Equipment Management

• Coordinate component supplier nominations, including intercompany suppliers, and ensure the required documentation and approvals are completed.
• Manage supplier nomination documentation, including Supplier Nomination Letters (SNL), as applicable.
• Identify, nominate, and manage suppliers for tooling, equipment, and gauges.
• Coordinate the procurement process and ensure timely release of purchase orders for tooling, equipment, and gauges.
• Prepare RFQs following supplier nomination and coordinate commercial follow-ups.
• Confirm profitability baselines and ensure costing information is accurate and up to date.

C. Production Launch and Process Validation

• Coordinate prototype builds and manage off-tool and off-process part production.
• Monitor and update long-run production results.
• Plan operator training and ensure skill qualification requirements are met.
• Coordinate internal Run-at-Rate (R@R) and customer Run-at-Rate activities, wherever applicable.
• Conduct and coordinate fitment and functional testing, customer trials, and process validation activities.
• Ensure production readiness by integrating customer demand, logistics requirements, and production planning.
• Support successful product and process launches in line with customer requirements and project timelines.

D. Quality, PPAP, and Customer Coordination

• Coordinate Production Part Approval Process (PPAP) activities and support customer visits and program review meetings.
• Ensure readiness for program audits and OPMS audits with respect to Process Engineering deliverables.
• Manage Safe Launch activities and review implementation progress.
• Coordinate with cross-functional teams to ensure compliance with customer-specific requirements and quality standards.
• Track and close Process Engineering deliverables within the agreed project timeline.

E. Project Management and Performance Monitoring

• Maintain and update Process Engineering KPIs on a monthly basis.
• Track and update Process Engineering deliverables weekly in line with the overall program timeline.
• Participate in program OBEYA meetings for all projects to review progress, risks, and action plans.
• Monitor project milestones and coordinate with internal teams, suppliers, and customers to ensure timely completion of deliverables.
• Ensure process documentation, production readiness, and audit requirements are completed before the relevant project milestones.

3. Key Competencies

• Strong analytical and problem-solving skills.
• Good understanding of automotive manufacturing and new product introduction (NPI).
• Knowledge of PFMEA, DFMEA, MBOM, EBOM, SAP, PPAP, and process validation.
• Experience in tooling, equipment, gauge management, and supplier development coordination.
• Strong project coordination and customer-handling skills.
• Ability to manage multiple project deliverables and meet deadlines.
• Good communication and cross-functional coordination skills.