Senior Process Engineer

Role overview

Process and tooling development

• Develop tooling processes and designs incorporating innovative technology, safety, and ergonomics.
• Align process work with the standard Bill of Process across engineering, build, installation, commissioning, and launch.
• Coordinate with Product Design on manufacturing feasibility and apply Lean principles to development requests.
• Develop tooling, Minimum Quantity Lubrication improvements, and tool management software for launches.
• Optimize tooling processes and introduce technologies for continuous improvement and cost reduction.
• Develop tooling master schedules and guide cost-reduction implementation.

Manufacturing systems delivery

• Design, approve, run off, deliver, and launch cutting tools; plan and facilitate the tool crib for new programs.
• Prepare tooling RFQs, compare supplier quotations, select suppliers, and complete procurement.
• Develop technical specifications and lead supplier pre-witness, drawing approval, DFMA, and tool-layout approval.
• Lead machine prove-out, monitor cycle times, and coordinate process improvements before vendor run-off.
• Lead machine installation, commissioning, witness activities, MAC sign-off, and issue resolution.
• Coordinate cross-functional teams on machine prove-out and tool-change capability.
• Develop process documents including DCP, PFMEA, process sheets, illustrations, and tool setup drawings.
• Ensure timely delivery of OEM tooling drawings, layouts, and cycle charts; address tooling PTR and ECCAR issues.

Cutting-tool responsibilities

• Select, specify, and design cutting tools for materials and machining operations.
• Analyze speeds, feeds, and depth of cut to improve tool life, cycle time, and surface finish.
• Analyze tool wear and failure modes to improve tooling strategy.
• Troubleshoot shop-floor issues including chatter, chipping, premature wear, and dimensional inconsistencies.
• Support new launches with tooling packages, feasibility studies, and prototype and production trial validation.
• Work with suppliers on new technologies, pricing, procurement, and delivery timelines.
• Collaborate with CNC programmers on toolpaths and cutting strategies.
• Track tooling consumption and crib inventory; identify savings through standardization or alternative tooling.
• Maintain tooling standards, specifications, cutting-parameter sheets, and tool-life data.

Qualifications

• Diploma or degree in Automotive, Electrical, Industrial, Manufacturing, Mechanical, Production, or another engineering discipline.
• A Master of Science is preferred.