Process Manufacturing Specialist

Job Description

Job Description

Objective of the Position: 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 / foot print 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.