Process Engineer

Job Title: Process Engineer – Automotive Lighting Job Summary The Process Engineer is responsible for designing, developing, optimizing, and maintaining manufacturing processes for automotive lighting systems (headlamps, tail lamps, interior lighting). The role focuses on improving efficiency, ensuring product quality, reducing costs, and supporting new product launches in a fast-paced automotive environment. Key Responsibilities 1. Process Development Optimization Develop and implement manufacturing processes for lighting components (injection molding, assembly, electronics integration). Analyze existing processes and identify improvements in cycle time, yield, and efficiency. Apply Lean Manufacturing, Six Sigma, and continuous improvement methodologies. Optimize workstation layout and line balancing. 2. New Product Introduction (NPI) Support industrialization of new lighting products from design to mass production. Participate in Design Reviews (DFM/DFA – Design for Manufacturing/Assembly). Create process flow diagrams, PFMEA, and control plans. Coordinate trials, pilot runs, and ramp-up activities. 3. Equipment Tooling Management Define specifications for manufacturing equipment and automation. Support installation, commissioning, and validation of machines. Troubleshoot equipment/process issues and implement corrective actions. Work with suppliers for tooling, jigs, fixtures, and automation systems. 4. Quality Assurance Ensure processes meet automotive quality standards (IATF 16949, ISO 9001). Monitor KPIs: scrap rate, first-pass yield, OEE. Lead root cause analysis (8D, Fishbone, 5 Why). Implement poka-yoke and mistake-proofing solutions. 5. Documentation Compliance Prepare and maintain process documentation: Work Instructions (WI) SOPs Control Plans Process Flow Charts Ensure compliance with customer-specific requirements (OEM standards). 6. Cross-functional Collaboration Work closely with R D, Quality, Production, Maintenance, and Supply Chain teams. Interface with customers and suppliers during audits and technical discussions. Support continuous improvement and cost reduction projects.