Lean Assembly Process Engineer: Drive CI, DFMA & Quality

DexSys (Magna); Lansing (MI); On-site; USD 85,000 - 110,000; Full time

Job summary

Magna Exteriors is seeking a hands-on manufacturing professional to join DexSys and help optimize processes, improve equipment performance, and drive operational excellence.

You will collaborate with assembly teams to ensure smooth production, apply Lean principles, and support new program launches through DFMA and process optimization. The role emphasizes continuous improvement and strong quality focus.

Responsibilities

• Continuously improve manufacturing processes using Lean Manufacturing principles to enhance labor efficiency, productivity, and quality.
• Support new program launches by developing process flows, cell layouts, component flow plans, cycle-time estimates, and labor requirements, while tracking builds through pre-SOP activities.
• Collaborate with APQP teams and Engineering on new program launches and component changes, implementing Design for Manufacturing and Assembly (DFMA) strategies.
• Assist in developing work instructions, Process FMEAs, and Control Plans related to new processes and process changes.
• Lead and participate in cross-functional team activities focused on maintaining and continuously improving departmental KPIs.
• Monitor departmental performance objectives and track continuous improvement metrics within CI teams.
• Support the investigation of customer and internal quality concerns and assist in developing and implementing corrective action plans to improve products and processes.
• Communicate process changes and provide training to Quality Technicians, Team Leaders, and team members to ensure effective implementation.
• Develop and implement error-proofing (Poka-Yoke) solutions to prevent assembly errors and improve process reliability.
• Research and evaluate new manufacturing technologies, benchmarking solutions against other Magna divisions and manufacturing facilities to determine applicability and potential benefits.
• Participate as a member of the Ergonomics Committee by identifying ergonomic concerns and helping develop solutions to improve workplace safety and efficiency.
• Serve as a Lean Thinker Champion by leading a designated production area in the Lean Thinker program and promoting continuous improvement initiatives.

Job description

Magna Exteriors is seeking a hands-on manufacturing professional to join DexSys and help optimize processes, improve equipment performance, and drive operational excellence.

You will collaborate with assembly teams to ensure smooth production, apply Lean principles, and support new program launches through DFMA and process optimization. The role emphasizes continuous improvement and strong quality focus.