Process Engineer - Engine Assembly

Process Engineer – Engine Assembly Ford Powertrain Manufacturing Engineers contribute to the design and production of advanced engines and propulsion systems. This role is responsible for developing and implementing assembly systems that support efficient, safe, and high-quality engine manufacturing operations. The successful candidate will work closely with Product Development, Manufacturing, Quality, Logistics, and suppliers to ensure robust assembly processes, efficient material flow, and successful program launches. The position requires a strong understanding of assembly engineering principles, manufacturing systems, process optimisation, and continuous improvement methodologies. Process Design & Development Develop and optimise engine assembly process flows, line layouts, and workstation designs. Design assembly stations with a strong focus on ergonomics and safety. Prepare process sheets, work instructions, and Standard Operating Procedures (SOPs). Support new model launches, engineering changes, and assembly process modifications. Evaluate assembly feasibility and incorporate Design for Manufacturing (DFM) and Design for Assembly (DFA) principles. Conduct time studies, motion studies, and line balancing activities. Equipment & Tooling Specify, design, and validate assembly equipment, fixtures, tooling, and automation systems. Coordinate equipment design reviews, installation, commissioning, and buyoff activities with suppliers. Ensure equipment meets safety, quality, productivity, and ergonomic standards. Support assembly equipment troubleshooting and process optimisation. Quality & Continuous Improvement Conduct root cause analysis and implement corrective actions for manufacturing and quality issues. Support Process Failure Mode and Effects Analysis (PFMEA), Control Plans, and error-proofing (Poka-Yoke) implementation. Lead Lean Manufacturing, Kaizen, and Six Sigma improvement projects. Improve productivity, reduce waste, and optimise manufacturing cycle times. Capacity Planning & Material Flow Support capital planning and cost estimation for assembly projects. Perform capacity analysis, line balancing, and takt time calculations. Evaluate material handling and feeding systems to improve assembly line efficiency. Implement Lean material flow principles within manufacturing layouts. Safety & Compliance Ensure manufacturing processes comply with health, safety, and environmental regulations. Conduct manufacturing risk assessments and implement safety improvements. Support compliance with Ford and industry manufacturing standards. Supplier & Documentation Support Support procurement activities related to manufacturing equipment and tooling. Participate in supplier evaluations and technical reviews. Manage OEM documentation, including installation manuals, spare parts lists, preventive maintenance plans, and engineering drawing packages. Ensure documentation is complete before project closure. Education Bachelor’s Degree in: Mechanical Engineering Manufacturing Engineering Production Engineering Industrial Engineering Automotive Engineering Electrical Engineering Experience 3–5 years of experience in manufacturing engineering, process engineering, or assembly engineering. Experience in automotive, powertrain, or high-volume manufacturing environments preferred. Experience supporting new product launches and assembly process implementation. Experience Level Mid Level