Process Manufacturing Specialist

Process Manufacturing Specialist

The Process Manufacturing Specialist is responsible for developing and standardizing advanced manufacturing processes in the automotive industry, focusing on robotics, automation, and quality control. They support cross-functional teams to optimize production efficiency, ensure product quality, and implement cutting-edge technologies across multiple plants. This role requires extensive experience in process engineering and project management, as well as the ability to drive continuous improvement initiatives. The specialist plays a critical role in aligning manufacturing operations with company goals, ensuring that production processes meet industry standards and customer expectations.

Accountabilities

The position incumbent ensures that:

• Create agreement for operational handover to plant at gate 4.1 / buy off.
• Create standards with managers to drive templates/procedures.
• Create a welding, datum and tolerance standard in NA for Commercial Vehicles and Passenger Vehicles.
• Determine max speed of weld robots based on material type and thickness.
• Support quality in the standard for gauges (drawing, fixture, and gauge).
• Drive standard for validating fixtures that don't have gauges released or don't have capital.
• Review what economically makes sense for MOD subs / MOD finals.
• Develop fixture R&R for fixture loading and clamping repeatability.
• Develop standard with quality for CPK/PPK value at buy off and final acceptance.
• Drive lessons learned process with plants at gate 5 for continuous improvement on successor or PV/CV similar products / equipment / concepts.
• Review Gate 2 and 3 to determine best approach on the following:
• Concept development / SMAC review
• Lead committee for SMAC, SOR, and simulation approvals
• Drive committee with emergency concepts at plants
• Work with QU to understand best design for mating parts at leak tester in final assembly.
• Support the development of direct measurement systems for leak testing to provide automatic weld repair.
• Develop direct measurement system for MIG/MAG welding with auto repair welding.
• Develop AI Cut/Etch/Polish software with lead/most stable technology plant.
• Standardize with plants on when backflush points are needed/P-numbers/just drawings for gauges.
• Work with fixture development team to drive standard process for operator understanding of part presence sensors.
• Work with equipment team to drive MIG/MAG vs. MicroMig/CMT vs. K-F Pulse.
• Further develop parameters based on material, robot speed, push/pull, thickness of stamped component, weld joint, gas mixture, weld wire diameter.
• Develop auto unload for finished goods with robot (3D scanning + roller system for staging of finished goods bin).
• Utilization overview of each piece of equipment per value stream.
• Develop process with component team for shared equipment to maximize / right size equipment utilization based on risk evaluation.
• Reduce batch buffers / footprint by driving 1-piece flow.
• Reduce changeover time with respective managers (welding/finals vs. sub-assemblies).
• Review AMR 1500/300kg for auto transfer to finished goods.
• Support payment term development for tooling and capital, along with clauses for late and performance penalties.
• Drive audit process with JC for yearly review on work centers, plant mapping/layout, Ti, Tq, Tr and routings.
• Show SMAC to actual deltas, provide direction, and align with plants to resolve issues.

Requirement Profile

Professional Background / Basic Qualification / Work Experience:

• Bachelor's Degree (B.A.) in Mechanical Engineering or within closely related field.
• Minimum 5 years of experience in Manufacturing/Process Engineering.
• Minimum 5 years of experience in Process Development and Implementation.
• Minimum 5 years of experience in working for an automotive manufacturing supplier.
• Advanced Manufacturing Technology experience.
• Ability to travel domestically by car or plane.
• To perform this job successfully, an individual should be proficient in Microsoft Office, SAP, nCode, and PAK (or similar) data collection system.

Technical Expertise:

• Proficiency in CAD software (e.g., AutoCAD, SolidWorks) for designing fixtures, gauges, and manufacturing layouts
• Ability to apply mathematical concepts and operations, including calculations, percentages, etc.
• Ability to read and comprehend simple instructions, short correspondence, and memos, and write simple correspondence.
• Analytical- Synthesize complex or diverse information; Collects and researches data; Uses intuition and experience to complement data; Designs work flows and procedures.
• Business Acumen- Understands business implications of decisions.
• Knowledge of continuous improvement of products for manufacturability.
• Knowledge of engineering fundaments, mechanical systems, electrical systems, automotive systems, and exhaust systems.
• Project Management- Develops project plans; Coordinates projects; Communicates changes and progress; Completes projects on time and budget; Strives to continuously improve expertise, knowledge and skills.