Senior Process Engineer

EControls; San Antonio (TX); On-site; USD 85,000 - 115,000; Full time

Job summary

EControls is seeking a Process Engineer with 5-10 years of manufacturing experience to design production processes, optimize assembly lines, and ensure readiness for high-volume operations.

You will support new product development, lead PFMEA/DFMEA activities, analyze data, and implement lean and Six Sigma improvements in collaboration with design, test engineering, and operations.

Qualifications

• B.S. in Electrical or Mechanical Engineering, or similar engineering discipline.
• 5-10 years of high-volume manufacturing environment experience.
• Knowledge of FMEA, PPAP, MSA, and Root Cause Failure Analysis is required.
• Ability to communicate effectively with design/test engineering, and manufacturing.
• Experience with lean manufacturing and Six Sigma methodologies.

Responsibilities

• Design experiments to develop optimum production processes across manual/auto assembly, inspection, and testing.
• Identify and solve production related issues and plan capacity for assemblies.
• Ensure production readiness of key processes and troubleshoot equipment problems.
• Drive process efficiency improvements by analyzing workflows and updating work instructions.
• Lead PFMEA/DFMEA together with data collection and analysis.
• Support quality with SPC, DMAIC, and risk reduction activities.
• Collaborate with design/test engineering and manufacturing teams.

Skills

Lean manufacturing

Six Sigma

Root cause analysis

Statistical process controls

Effective communication

Education

B.S. in Electrical or Mechanical Engineering

Job description

Description

EControls is a global provider of innovative, state-of-the-art integrated controls solutions for internal combustion engines and electric drive systems in the off-highway, on-highway, and stationary equipment markets. EControls designs world-class, full-authority engine management systems for major OEMs around the world. Our global engine development labs and engineering staff offer full-range support, from design guidance for base engine conversion to hardware, software, and engine calibration to meet each application's specific requirements.

We are passionate about customer satisfaction and service. We fearlessly engage in any effort that will eliminate our customers’ risk and clear a path to their success. We immerse ourselves in our customers’ world, reveal unknowns and deliver integrated solutions.

We are looking for a Process Engineer with 5-10 years or more years of manufacturing industry experience, ideally with time spent working in one or more engineering discipline. (Mechanical, Electrical, Software or Application Engineering)

Support Manufacturing Operations

• Design experiments to develop optimum production processes - manual assembly, automated assembly, press operations, automated inspection, and testing
• Identify and solve production related issues
• Plan and develop processes and capacity utilization strategy for assembly operation of mechanical, electro-mechanical, and electrical components
• Ensure production readiness of key processes
• Troubleshoot root cause for equipment and process related problems
• Drive process efficiency improvements by analyzing existing work flows and developing alternative solutions
• Create work instructions & procedures and update existing
• Conduct time studies, modify BOMs and routings

Support New Product Development and Continuous Improvement Efforts

• Design for manufacturability input into product designs
• Define assembly strategy for production
• Design new assembly equipment & tooling
• Lead PFMEA development and participate in DFMEA development
• Collect and analyze data from assembly operations
• Improve existing fixtures and tooling
• Explore & implement cost reduction ideas
• Identify, source, and set up critical spare parts for production cells
• Able to interpret assembly and component drawings and the requirements within

Support Quality

• Develop and execute statistical process controls utilizing appropriate quality tools plus statistical techniques.
• DMAIC: Define, measure, analyze, improve and control
• Root cause analysis and risk reduction: 5Y, FMEA, 8D
• Problem solving (product/process)
• Participate in MRB (Material Review Board) process to review Non-Conforming Material as needed to support production operations

Requirements

• B.S. in Electrical or Mechanical Engineering, or similar engineering discipline
• A minimum of 5-10 years of high-volume manufacturing environment experience
• Failure mode analysis and process control implementation experience preferred
• Knowledge of FMEA, PPAP, MSA, and Root Cause Failure Analysis is required
• Ability to communicate effectively with design/test engineering, and manufacturing
• Experience with lean manufacturing and Six Sigma methodologies