We are seeking a Process Engineer to lead the launch of the new Stator process within the eMotor project. In the Front of Line area (from OP10 to OP70), you will be responsible for controlling and ensuring process characteristics, strongly supported by quality engineering tools (DFMEA, PFMEA, Control Plan, Process Illustration, Part Print and Reaction Plan). You will implement the SPC strategy, manage scrap reduction due to common cause variation, and report process capability monthly, while maintaining effective communication with Production, Maintenance, Quality, PTME, Suppliers and OEM.
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Front of Line Process Control: Ensure and control that Stator characteristics meet technical specifications from OP10 to OP70.
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Gauges & Measurement: Implement and maintain gauges and control devices specific to the FoL Process to guarantee product quality.
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Personnel Training: Train, coach, and certify production personnel on FoL process standards, operating procedures, and reaction plans.
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Technical & Quality Documentation: Continually develop, update, and validate DFMEA, PFMEA, Control Plan, Process Illustration, and Part Print.
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SPC Strategy and Reporting: Implement and oversee the SPC strategy (sampling design, control charts, variability analysis, and Cp/Cpk - Pp/Ppk calculation) and prepare monthly capability reports.
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Monitoring and Improvement of Quality Metrics: Regularly monitor and optimize key metrics such as First Time Through (FTT) and Rolled Throughput Yield (RTY).
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Scrap Reduction: Design and execute action plans focused on reducing process scrap by resolving key issues related to common cause variation.
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Engineering Change Management and Reaction Plans: Lead Engineering Change Management (MTC) and structure robust reaction plans for process deviations.
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Problem Solving and Lean Manufacturing: Apply structured methodologies (Global 8D, Six Sigma, or equivalent) and Lean Manufacturing tools (including Value Stream Mapping - VSM).
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Ergonomics and Process Robustness: Conduct ergonomics studies on workstations and implement Poka Yoke and Error Proofing systems to prevent operational errors.
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Process Audits: Actively participate in process and quality system audits (such as ISO 9001 and IATF 16949) to ensure compliance.
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Cost Reduction: Propose and implement continuous improvement ideas to reduce manufacturing costs without compromising quality.
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Consumables Management: Identify, classify, and maintain optimal levels of consumables and product-contact parts to ensure operational continuity.
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Cross-Functional Collaboration: Work in synergy with Production, Maintenance, Quality, PTME, and external suppliers to resolve issues and meet project milestones.
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Professional Reporting: Prepare professional-grade reports and presentations to clearly explain issues, investigations, and corrective actions to management and involved areas.
Education
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Bachelor’s degree in Engineering (Mechanical, Industrial, Electrical, Mechatronics, or a related field).
Experience
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Strong, demonstrable experience launching manufacturing processes, preferably in the automotive sector, electric motors, or high-precision electrical components.
Languages
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Fluent English (B2/C1 level equivalent), with excellent technical communication, reading, and writing skills.
Technical Knowledge
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Proficiency with Core Tools (DFMEA, PFMEA, Control Plan).
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Advanced ability to interpret technical drawings (Part Prints) and Process Illustrations.
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Statistical Process Control (SPC) and Process Capability analysis (Cp/Cpk – Pp/Ppk).
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Structured problem-solving methodologies (Global 8D, Six Sigma, or equivalent).
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Lean Manufacturing tools and Process Mapping (Value Stream Mapping).
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Poka Yoke and Error Proofing design.
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Knowledge of quality standards and audits (ISO 9001, IATF 16949).
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Ergonomics applied to production lines.
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Monitoring and improving quality KPIs (FTT, RTY).
Soft Skills
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Analytical thinking and complex problem-solving abilities.
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Leadership, proactivity, and a results-driven mindset.
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Strong communication and technical writing skills.
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Ability to work effectively in cross-functional, multidisciplinary teams.
DISCLAIMER: Ford Motor Company is an Equal Opportunity Employer, as we are committed with a diverse workforce, and do not discriminate against any employee or applicant for employment because of race, color, sex, age, national origin, religion, sexual orientation, gender identity and/or expression, status as a veteran and basis of disability.
