Process Engineer - Powertrain Assembly

The Process Engineer - Powertrain Assembly will support the design, development, launch, and continuous improvement of engine and transmission assembly processes at Ford's Chennai facility.

Responsibilities

Process Design & Development

• Develop and optimise engine and transmission assembly processes for new and existing programs.
• Design manufacturing process flows, workstation layouts, and assembly line configurations.
• Create and maintain process documentation, including work instructions and standard operating procedures.
• Support product launches, engineering changes, and process improvements.

Equipment & Tooling

• Define requirements for assembly equipment, fixtures, tooling, and automation systems.
• Coordinate equipment design reviews, installation activities, and commissioning with suppliers.
• Validate equipment performance and ensure compliance with safety, quality, and ergonomic standards.

Quality & Continuous Improvement

• Investigate manufacturing issues using structured problem-solving methodologies and root cause analysis.
• Implement corrective and preventive actions to improve process stability and product quality.
• Support Process Failure Mode and Effects Analysis (PFMEA), control plans, and error-proofing initiatives.
• Drive Lean Manufacturing, Six Sigma, and Kaizen projects to improve productivity, reduce waste, and optimise cycle time.

Capacity Planning & Cost Management

• Support capital investment planning and cost estimation activities.
• Conduct line balancing, capacity analysis, and takt time studies.
• Evaluate material handling and feeding systems to improve operational efficiency.

Safety & Compliance

• Ensure manufacturing processes comply with all applicable health, safety, and environmental requirements.
• Perform risk assessments and implement workplace safety improvements.

Supplier & Procurement Support

• Prepare and issue Requests for Quotation (RFQs) to suppliers.
• Review technical and commercial proposals and support supplier selection activities.
• Support purchase order processing in accordance with procurement procedures.

Documentation Management

• Manage receipt and validation of supplier documentation, including maintenance manuals, spare parts lists, reliability reports, installation drawings, and preventive maintenance plans.
• Track document completion and resolve outstanding issues with equipment suppliers before project closure.

Qualifications

Education

• Diploma or Bachelor's Degree in Mechanical Engineering, Manufacturing Engineering, Production Engineering, Automotive Engineering, Industrial Engineering, Electrical Engineering, or a related discipline.

Experience

• 3 to 5 years of manufacturing engineering experience within automotive production environments.
• Experience in engine and/or transmission assembly operations is preferred.

Technical Skills

• Strong knowledge of engine and transmission assembly processes.
• Experience with manufacturing equipment, tooling, and automation systems.
• Proficiency in AutoCAD, CATIA, or equivalent CAD software.
• Understanding of:
• PFMEA
• Control Plans
• GD&T (Geometric Dimensioning & Tolerancing)
• Lean Manufacturing
• Six Sigma methodologies
• Capacity planning and line balancing

Professional Skills

• Strong analytical and problem-solving abilities.
• Effective communication and presentation skills.
• Ability to work successfully in cross-functional teams.
• Experience supporting new product launches and manufacturing projects.