Manufacturing E-Motor Process Engineer

The PAC Group; München; On-site; EUR 71,000 - 100,000; Full time

Benefits offered by this job

International project

Onsite in Saudi Arabia

Structured training

Job summary

The PAC Group is seeking a Senior Process Engineer to join a long‑term, onsite project in Saudi Arabia. You will own process definition, drive line balancing, and lead commissioning, qualification, and ramp‑up to full production on an e‑drive assembly line.

You will manage DOE, PFMEA, 8D/5-Why analyses, and establish SPC data foundations across MES and traceability systems. Relocation for the project duration (Sept 2026–Dec 2027) is required.

Qualifications

• MSc or equivalent engineering degree in Mechanical, Electrical, Mechatronic, Manufacturing, Materials, Industrial Engineering, or related field.
• 5–10 years of process engineering experience in high-volume manufacturing, automotive preferred.
• Hands-on ownership of a manufacturing process at rate, not only design.
• Strong knowledge of takt-based manufacturing, line balancing, OEE, and downtime reduction.

Responsibilities

• Own the process definition for assigned perimeter, including flow, cycle time, parameter windows, control plans, PFMEA, and change control.
• Lead equipment commissioning, SAT, DOE planning and initial parameter setting.
• Deliver APQP and PPAP requirements for your area.
• Engineer to takt by balancing stations and removing bottlenecks and micro-stops.
• Drive ramp-up to full production and manage scrap, rework and yield data.
• Act as escalation point for production, using 8D, 5-Why, Ishikawa and Shainin.
• Design and validate error-proofing and in-line verification.
• Build data foundation through SPC, MES, traceability systems and monitoring.
• Collaborate with customers and suppliers on PPAP and JIT/JIS topics.
• Support safety, HV work practices, and EHS risk assessments.

Skills

Takt-based manufacturing

English communication

Problem solving

On-site execution

Education

MSc in Engineering

Tools

Minitab

JMP

Python

R

DOE

MSA/Gage R&R

SPC

Job description

Location: Kingdom of Saudi Arabia (KSA) – 100% Onsite / Relocation Required
Project Duration: September 2026 – December 2027
Level: Senior
Client Facing: Yes
Contract Type: TBD
Language: English mandatory

This is a long-term, onsite international project based in the Kingdom of Saudi Arabia (KSA), anticipated to run from September 2026 through December 2027.Candidates must be willing and able to relocate to and reside in Saudi Arabia for the duration of the project and work full-time at the client’s manufacturing site. This is not a remote, hybrid, or rotational assignment.

Please apply only if you are comfortable relocating to Saudi Arabia and maintaining an onsite presence for the duration of the project.

About The PAC Group

At The PAC Group (PAC), we specialize in engineering consulting, program management, and operational excellence, delivering high-impact solutions in more than 20 countries. For more than 41 years, we have partnered with leading companies across the automotive, aerospace, industrial, and technology sectors, providing strategic guidance and hands‑on execution that drive innovation and efficiency.

Whether launching advanced manufacturing systems, deploying digital simulation tools, or scaling global operations, PAC thrives at the intersection of technology, engineering, and problem‑solving.

Joining PAC means joining a dynamic, fast‑paced, global team that values curiosity, collaboration, and continuous improvement.

Role Purpose

PAC is supporting a client launching an electric drive unit manufacturing line in Saudi Arabia involving the e‑motor and inverter through integrated e‑drive assembly and end‑of‑line testing. The line will supply a vehicle assembly plant.

The role covers equipment installation and commissioning, process qualification, run-at-rate, PPAP, Start of Production (SOP), and ramp‑up to full-volume production.

We are recruiting several Process Engineers. Depending on your background, you will take deep ownership of one process area—stator, rotor, motor assembly and test, gearbox, or inverter and power electronics—or work as a cross‑process generalist owning an end‑to‑end value stream.

Candidates should identify which profile best aligns with their experience so the project scope can be matched accordingly.

Key Responsibilities

• Own the process definition for your assigned perimeter, including process flow, cycle‑time allocation, parameter windows, control plans, PFMEA, work instructions, and change control from installation through stable‑rate production.
• Lead equipment commissioning, SAT, process capability studies, and qualification runs; define and execute DOE activities to establish initial parameter windows.
• Deliver APQP and PPAP requirements for your assigned area.
• Engineer to takt by balancing stations and eliminating bottlenecks and micro‑stops.
• Drive the production ramp curve by converting scrap, rework, first‑pass yield, and downtime data into a prioritized improvement backlog and closing gaps to full‑rate production.
• Act as the first‑line technical escalation point for production, leading structured problem‑solving methodologies including 8D, 5‑Why, Ishikawa, and Shainin.
• Make containment decisions in partnership with Production and Quality.
• Design and validate error‑proofing, including poka‑yoke, in‑line verification, torque and force‑displacement monitoring, and part traceability.
• Build the process data foundation through SPC on critical characteristics, MES and traceability systems, and statistical monitoring.
• Support customer and supplier interfaces, including sequenced JIT/JIS delivery requirements, customer‑specific requirements, supplier PPAP for incoming components, and problem‑solving with equipment and component suppliers.
• Contribute to safety and compliance activities involving high‑voltage work practices, permanent magnet handling, press and laser safety, chemical and adhesive handling, ergonomics, and EHS risk assessments.
• Train and coach production technicians and operators on process fundamentals, critical parameters, troubleshooting, and reaction plans.

Required Qualifications

• MSc or equivalent engineering degree in Mechanical, Electrical, Mechatronic, Manufacturing, Materials, Industrial Engineering, or a related discipline.
• Minimum of 5–10 years of process engineering experience in high-volume manufacturing, ideally within automotive powertrain/components, electric motors, electronics, or comparable takt‑driven assembly environments.
• Hands‑on production‑floor experience with direct ownership of a manufacturing process at rate—not solely process design or engineering experience.
• Strong working knowledge of takt‑based manufacturing, including cycle‑time analysis, line balancing, OEE, bottleneck analysis, and downtime reduction.
• Practical experience using statistical tools including SPC, DOE, MSA/Gage R&R, and capability analysis with tools such as Minitab, JMP, Python, or R.
• Strong command of automotive quality methodologies, including PFMEA, control plans, 8D, root‑cause analysis, APQP, and PPAP.
• Ability to work effectively with manufacturing data from MES, SCADA, historians, traceability systems, and test databases.
• Strong written and verbal English communication skills and the ability to confidently defend technical positions with management, customers, and suppliers.
• Ability and willingness to relocate to Saudi Arabia and reside in KSA for the full project duration, anticipated from September 2026 through December 2027.
• Ability to work 100% onsite at the client’s manufacturing facility throughout the assignment.

Preferred Qualifications

• Direct experience with electric motor, e‑axle, or power electronics manufacturing.
• Experience supporting a greenfield launch or major capacity ramp, including commissioning, qualification, run‑at‑rate, SOP, and ramp to full production.
• IATF 16949 experience and exposure to customer‑specific requirements and customer audits.
• Experience supplying a vehicle assembly plant under JIT or JIS sequenced delivery requirements.
• Joining‑process expertise relevant to e‑drives, including laser welding, ultrasonic or wire bonding, sintering, press‑fit, and interference joining.
• Technical cleanliness experience under ISO 16232 / VDA 19 and ESD control.
• High‑voltage certification or qualification to work on HV systems.
• Lean or Six Sigma certification (Green Belt or Black Belt).
• Experience with automation, robotics, and vision systems.
• Previous experience working internationally or within the Middle East is beneficial but not required.

How You Work

• Comfortable operating with ambiguity and incomplete data—a production ramp does not wait for perfect information.
• Strong bias toward the production floor: you go and see, measure, investigate, and build conclusions from evidence.
• Rigorous about documentation and change control because a process that is not documented cannot effectively be transferred or scaled.
• Collaborative across functions and cultures and able to maintain and defend a technical position under pressure.
• Comfortable working as part of an international, multicultural team while embedded onsite with the client.

What Success Looks Like

• Your process area is qualified, run‑at‑rate is passed, and PPAP is submitted and approved according to customer timing.
• Stations within your perimeter maintain net cycle time within takt allocation, with OEE meeting or exceeding the ramp plan.
• First‑pass yield follows the planned ramp curve, with top scrap and rework drivers ranked, understood, and actively addressed.
• Zero customer line stoppages attributable to your process area; any escape has a verified root cause and permanent countermeasure rather than containment alone.
• Process documentation—including control plans, PFMEA, work instructions, parameter windows, and reaction plans—is complete, current, and actively used by production.
• Production technicians within your area are capable of operating and troubleshooting the process independently.

Working Conditions & International Assignment Requirements

• This position requires relocation to and residence in the Kingdom of Saudi Arabia for the duration of the project, currently anticipated from September 2026 through December 2027.
• The position requires full‑time, 100% onsite presence at the client’s manufacturing facility in Saudi Arabia.
• This is not a remote, hybrid, fly‑in/fly‑out, or rotational assignment.
• Candidates must be prepared to establish temporary residence in Saudi Arabia for the project period.
• Regular to full‑time work will occur within production areas, dry rooms, and cleanrooms with associated PPE and gowning requirements.
• During commissioning, qualification, SOP, and ramp phases, flexibility in working hours and periodic shift or weekend support will be expected.
• No routine travel to equipment suppliers, partner plants, or R&D sites is currently anticipated.
• International assignment and work authorization requirements will apply based on candidate eligibility and project requirements.

What We Offer

• The opportunity to play a key role in a major international greenfield manufacturing launch.
• A launch you can point to throughout your career: taking a manufacturing operation from installation and commissioning through SOP and full‑rate production.
• Structured training on technology and process methods, with exposure to the full manufacturing value stream.
• The opportunity to work directly with an international client and cross‑functional engineering teams on a high‑profile project in Saudi Arabia.

Voluntary Self-Identification

As set forth in The PAC Group’s Equal Employment Opportunity policy,we do not discriminate on the basis of any protected group status under any applicable law.