Process Engineer

Position Summary

Responsible for providing engineering support and expertise to Value Stream to optimise process capability, efficiency, and output. This includes the development, implementation, and continual improvement of manufacturing tools, processes, and systems in alignment with IATF 16949 standards. This role ensures that all activities are executed within agreed timelines while maintaining compliance with quality management requirements and driving best practices in process engineering.

Principle Responsibilities

• Lead and sustain continuous improvement initiatives across all manufacturing activities within the Value Stream, utilising Kaizen events, SMED, Six Sigma, and Value Stream Mapping.
• Drive implementation of Lean practices to eliminate waste, improve efficiency, and optimize flow throughout the workplace.
• Develop, validate, and optimize manufacturing processes to ensure compliance with IATF 16949 requirements, focusing on robust process controls and defect prevention.
• Support DFMEA and Process Failure Mode and Effects Analysis (PFMEA) for new products.
• Ensure all process and assembly equipment meets safety, quality, and capability standards, preventing hazards and ensuring ergonomic compliance.
• Specify, procure, and validate manufacturing equipment, tooling, and fixtures to meet production and quality requirements.
• Create and maintain clear, detailed work instructions aligned with company templates to support operator training and standardization.
• Support adherence to IATF 16949 standards by ensuring robust process documentation, risk assessments, and control plans.
• Collaborate with Quality teams to maintain product conformity and drive corrective actions using structured problem-solving methodologies (DMAIC, 8D).
• Develop and improve Health & Safety practices for all processes, ensuring compliance with site policies and legal requirements.
• Participate in risk assessments and implement preventive measures to mitigate hazards.
• Lead cost reduction initiatives through process optimisation, value engineering, and capital expenditure recommendations.
• Provide accurate product costings and feasibility analyses to support business objectives.
• Support team leaders in creating and updating training documentation & SOP’s
• Develop multi-skilled teams through structured training programs to enhance flexibility and resilience.
• Work with cross-functional teams to support New Product Development by ensuring manufacturing processes are integrated from concept to launch.
• Prepare and submit reports detailing capital expenditure requirements, including justification and cost analysis.
• Establish and maintain process capability studies and monitor performance against control limits.
• Implement error-proofing (Poka-Yoke) solutions to prevent defects at source.
• Develop control plans and ensure alignment with customer-specific requirements.
• Lead root cause analysis for process-related issues and implement permanent corrective actions.
• Ensure compliance with APQP and PPAP submissions for new product introductions.