Process 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

Job descriptions may display in multiple languages based on your language selection. What we offer: At Magna, you can expect an engaging and dynamic environment where you can help to develop industry-leading automotive technologies. We invest in our employees, providing them with the support and resources they need to succeed. As a member of our global team, you can expect exciting, varied responsibilities as well as a wide range of development prospects. Because we believe that your career path should be as unique as you are.

Group Summary: Cosma provides a comprehensive range of body, chassis and engineering solutions to global customers. Through our robust product engineering, outstanding tooling capabilities and diverse process expertise, we continue to bring lightweight and innovative products to market.

Job Responsibilities:

Process Improvement

• 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).

Quality and Risk Management

• Develop and drive usage of Process Failure Mode and Effects Analysis (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, etc.).
• 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.
• Collaborate and support Quality Assurance to sustain Layered Process Audits (LPA) as required.
• Ensure compliance with IATF 16949, Customer Specific Requirements, and the Internal Audit team’s schedule.

Change and Project Management

• Ensure process changes are aligned with MQS11 and our internal Change Management procedure.
• Participate as a Subject Matter Expert (SME) to support Cross Functional Teams (CFT) during Change Management feasibility studies.
• Apply and adhere to Advance Product Quality Planning (APQP) principles during project activities.

Continuous Improvement

• Use Lean tools to drive continuous improvement across all process (VSM, 5S, Kanban, etc.).
• Consider soft Lean principles to nurture engagement, offer coaching and mentorship, enable self-directed learning, and amplify continuous-improvement behaviours.
• Document and share Lessons Learned and Global Read Across with the wider team.

Data Analysis and Computer Literacy

• Work closely with operators and SMEs across departments to use data-driven decisions toward problem solving.
• Present findings, proposals, and outcomes clearly to all relevant stakeholders.
• Use internal IT solutions to help track and drive process performance (O365, Power Platform, etc.).

Environmental, Health & Safety Responsibilities

• Adhere to all Autolaunch's health, safety and environmental policies.
• Abide by and promote all safety and non-safety plant rules and regulations.
• Report any defects, hazards and non-compliance items to the department leadhand(s)/supervisor(s)/manager(s).
• Report any incident/accident to a first aider/ leadhand / supervisor/manager.
• Abide by the operating procedures/work instructions/maintenance practices and procedures of any equipment or machinery used.
• Wear personal protective equipment as provided by Autolaunch.
• Responsible for pre-operation inspections of respective equipment, machinery and vehicles so as to ensure proper and safe operation (Preventative Maintenance Checklist).
• Responsibility to keep work area clean and adhere to housekeeping/5S standards.
• Participate and assist in any investigation where required.

Key Qualifications & Requirements:

• 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 comfortable using data analysis software.
• Desirable Qualification in Process Engineering, Chemical Engineering, Mechanical Engineering, or related discipline.
• Experience with vision systems and Poka Yoke design.
• Exposure to chemical dosing systems and surface treatment processes.
• Yellow or Green belt in Lean Manufacturing or Six Sigma methodologies.
• Knowledge of ERP / MES systems.

Additional Information:

• Must adhere to Magna’s Code of Conduct and Ethics and all company policies.
• Must uphold confidentiality and act as a professional representative of Autolaunch.
• Willingness to travel and flexibility in working hours may be required based on program needs.
• Overtime may be required during program milestones or launch activities.
• Strong attendance and time management history required.
• Detail-oriented and analytical, with a strong focus on process science and repeatability.
• Tenacious to drive improvements and solve complex problems.
• Hands-on and practical, with a strong presence on the shop floor.
• Strong communicator and collaborator across departments.
• Proactive mindset with a drive to protect the customer and improve operational performance.
• Organised and methodical, able to manage multiple priorities effectively.
• Effective communicator through all necessary media.

Awareness, Unity, Empowerment:

At Magna, we believe that a diverse workforce is critical to our success. That’s why we are proud to be an equal opportunity employer. We hire on the basis of experience and qualifications, and in consideration of job requirements, regardless of, in particular, color, ancestry, religion, gender, origin, sexual orientation, age, citizenship, marital status, disability or gender identity.

Worker Type: Regular / Permanent Group: Cosma International

We see a future where everyone can live and move without limitations. That’s why we are developing technologies, systems and concepts that make vehicles safer and cleaner, while serving our communities, the planet and, above all, people. In the right environment, your ideas can turn into industry-changing automotive technologies and improve the lives of people around the world. Let's create the future of mobility, together.

Learn more about us: Sustainability Innovation Interview-Tips