General Assembly Process Engineer

Position Overview

We are seeking a skilled and motivated Process Engineer to support General Assembly (GA) operations in a high-volume automotive manufacturing environment. The GA Process Engineer will be responsible for developing, validating, and optimizing assembly processes for vehicle systems including trim, chassis, final line, and end-of-line (EOL) testing. This role plays a key part in ensuring safe, efficient, and high-quality production while supporting continuous improvement and new product introduction (NPI).

Key Responsibilities

Process Design & Optimization

• Design and implement robust and ergonomic manufacturing processes for General Assembly operations.
• Develop and maintain process documentation: Work Instructions, Standard Operating Procedures, Control Plans, and Process Flow Charts.
• Ensure process designs support quality, safety, and throughput targets.
• Maintain and verify the Bill of Process and ensure process updates reflect the latest engineering changes.

Validation & Launch Support

• Support new model launches by preparing and validating process layouts, tooling, and line balance.
• Conduct trial builds and process capability studies to ensure readiness for SOP.
• Participate in build events, station reviews, and cross-functional validation workshops.

Quality and Process Control

• Perform Process Failure Mode and Effects Analysis (PFMEA) to identify and mitigate process risks.
• Support quality teams with root cause analysis (5-Why, 8D) and implementation of corrective actions (ICA/PCA).
• Establish Statistical Process Control (SPC) and process monitoring systems to improve First Pass Yield (FPY) and reduce variability.

Cross-Functional Coordination

• Collaborate with Manufacturing Engineering, Product Engineering, Maintenance, Production, Quality, Material Flow, and Launch Teams to ensure processes are synchronized and optimized.
• Participate in line balancing, workstation design, and layout improvements.
• Provide engineering support for production issues and continuous improvement opportunities.

Change Management

• Manage engineering changes (ECRs, DRs, PCRs) by coordinating with relevant stakeholders and updating process documentation accordingly.
• Evaluate the impact of changes on tooling, facilities, material flow, and station cycle time.

Safety & Compliance

• Conduct safety risk assessments and ergonomic evaluations for all new or modified processes.
• Ensure compliance with plant safety policies, lockout/tagout, and hazard control standards.

Skills

Skills & Competencies

• Strong understanding of vehicle assembly processes (trim, chassis, final, EOL).
• Proficiency in PFMEA, process documentation, and lean manufacturing tools.
• Effective communication and cross-functional collaboration skills.
• Ability to troubleshoot production issues and implement sustainable solutions.
• Strong analytical skills and experience with data-driven decision-making.

Preferred Tools & Systems

• MES / Manufacturing Execution Systems
• 3DX / CAD tools
• ProPlanner / Dozuki / Smartsheet
• Minitab / Tableau / Power BI
• Torque monitoring systems (e.g., Atlas Copco)
• AutoCAD, CM4D, JIRA (for ECRs, PCRs, DRs)

Minimum Qualifications

• Bachelor’s degree in Mechanical, Industrial, or Manufacturing Engineering (or related field).
• 3–5 years of experience in automotive manufacturing, preferably in General Assembly or a related discipline.