Process Engineer - Powertrain Assembly

Ford; Chennai District; On-site; INR 900,000 - 1,500,000; Full time

Job summary

Ford in Chennai is seeking a Process Engineer - Powertrain Assembly to drive design, development, and continuous improvement of engine and transmission assembly processes. You will work on process flows, equipment needs, and documentation while supporting launches and changes.

The role requires hands-on experience in automotive manufacturing, CAD tooling, and a strong grasp of lean, Six Sigma, and PFMEA practices to ensure safe, efficient production operations.

Qualifications

• 3 to 5 years of manufacturing engineering experience in automotive production.
• Experience in engine and/or transmission assembly operations preferred.
• Knowledge of PFMEA, Control Plans, and GD&T is advantageous.

Responsibilities

• 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.
• 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 safety, quality, and ergonomic standards.
• Drive Lean Manufacturing, Six Sigma, and Kaizen projects to improve productivity, reduce waste, and optimise cycle time.
• Conduct line balancing, capacity analysis, and takt time studies.
• Support PFMEA, control plans, and error-proofing initiatives.
• Prepare and review supplier documentation and RFQs.

Skills

Analytical thinking

Problem solving

Cross-functional teamwork

Strong communication

Lean manufacturing

Six Sigma

Automotive manufacturing

Education

Diploma or Bachelor7s Degree in Mechanical Engineering

Tools

AutoCAD

CATIA

Job description

The Process Engineer - Powertrain Assembly will support the design, development, launch, and continuous improvement of engine and transmission assembly processes. The role requires strong technical knowledge of manufacturing systems, automation, quality tools, and lean manufacturing principles to deliver safe, efficient, and high-quality production operations.

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.