Automotive Process Improvement Engineer

Magna International Inc.; Bagenalstown; On-site; EUR 60,000 - 90,000; Full time

Job summary

Magna International Inc. in Ireland seeks an experienced Process Engineer to drive continuous improvement across core manufacturing lines for Cosma International. You will own, monitor, and optimize key processes to improve repeatability, cycle times and quality.

The role emphasizes PFMEA, Control Plans, and structured problem-solving (8D, 5Whys, Ishikawa), plus implementation of SPC, Poka Yoke and vision systems. Travel and shift flexibility may be required to support program milestones.

Qualifications

• Essential Hands-on experience in a manufacturing environment, ideally automotive or high-volume production.
• Strong understanding of process control, variation reduction, and quality assurance.
• Experience with PFMEA, Control Plans, and structured problem-solving tools (8D, 5 Whys, Ishikawa).
• Familiarity with automated assembly and chemical processing techniques.
• Proficiency in Microsoft 365 and data analysis software.
• Desirable Qualification in Process Engineering, Chemical Engineering, Mechanical Engineering, or related discipline.

Responsibilities

• Own, monitor, and optimise key manufacturing processes to ensure repeatability, stability, and quality.
• Conduct detailed process analysis to identify waste and opportunities for improvement.
• Develop robust process controls, standard operating procedures, and work instructions.
• Lead and support Part Trail Runs (PTR) for change-management validation.
• Monitor and improve cycle times, throughput, Overall Equipment Efficiency (OEE), and First Time Through / Quality (FTT/FTQ).
• Implement and maintain Statistical Process Control (SPC) to track and drive improvements in capability (Cp/Cpk).
• Develop and drive usage of PFMEA and Control Plan documentation to drive Continuous Risk Reduction (CRR).
• Lead structured Root Cause Analysis (RCA) activities using advanced Lean tools and techniques (8D, 5W1H, Ishikawa).
• Implement and maintain Poka Yoke, Vision Systems, and error-proofing, to prevent process failures.
• Support Production Part Approval Process (PPAP) submissions and dimensional capability studies.

Skills

Hands-on manufacturing experience

Process control

Data analysis software

Lean manufacturing

Problem-solving tools

Cross-functional collaboration

Education

Desirable Process Engineering

Chemical/Mechanical Engineering

Tools

Vision systems

Poka Yoke

ERP / MES systems

PFMEA / Control Plans

Job description

Magna International Inc. in Ireland seeks an experienced Process Engineer to drive continuous improvement across core manufacturing lines for Cosma International. You will own, monitor, and optimize key processes to improve repeatability, cycle times and quality.

The role emphasizes PFMEA, Control Plans, and structured problem-solving (8D, 5Whys, Ishikawa), plus implementation of SPC, Poka Yoke and vision systems. Travel and shift flexibility may be required to support program milestones.