Process Engineer Side Frame Assembly - Body in White

Summary
We are seeking an experienced and detail-oriented Process Engineer, highly skilled and experienced in Body-in-White (BIW) process with a specific focus on Framer process and side frame process. This role is critical in ensuring body assemblies meet stringent surface quality, dimensional accuracy and structural standards. The ideal candidate will have a strong background in BIW processes, welding and joining technologies, and experience in implementing and improving BIW standards or similar manufacturing environments.

You Will

• Develop, optimize and maintain Framing and Sides frame processes to achieve quality and dimensional tolerances in BIW assemblies.

• Define and implement process parameters, tools and techniques for achieving consistent joining and assembly for body structures.

• Lead feasibility studies for new product introduction and process changes.

• Ensure all process documentation (PFMEA, Control Plans, Standard Work, Process Flows) is complete and production ready.

• Collaborate with Operations, ME, and Quality to verify line readiness and address early build issues.

• Work closely with tooling and fixture design teams to ensure manufacturability and repeatability.

• Coordinate with equipment suppliers and integrators to ensure compliance with manufacturing and safety standards.

• Participate during process engineering activities for vehicle launch programs.

• Support prototype builds, pre-production trials, and ramp-up activities focused on metal finish and fit performance.

• Collaborate with cross-functional teams (ME, design, quality, logistics, production) to resolve fit, finish and surface quality issues during development and serial production.

• Coordinate process changes and line upgrades with minimal production disruption.

• Conduct root cause analysis for process-related quality issues for surface defects, weld distortions, panel misalignments and other body assembly issues.

• Define and implement corrective actions to reduce defects and improve process capability.

• Apply lean manufacturing and six sigma methodologies to drive continuous improvement initiatives.

• Capture lessons learned from launches and incorporate them into future programs.

• Create and maintain detailed process documentation including PFMEA, control plans, work instructions and standard operating procedures.

• Ensure compliance with internal standards, customer requirements, and regulatory guidelines.

• Understand the Buy Off Book process for handover from Manufacturing Engineering team for operation readiness.

You Bring

• Strong understanding of BIW tooling, fixtures, automation, joining and SPC processes.

• Proficiency in PFMEA, Control Plans, Process Audits, and quality gates.

• Familiarity with CAD tools, MES systems, and plant-floor digital manufacturing platforms.

• Understanding of GD&T, DFM/DFA, quality tools like G8D, 5-Why analysis, and automotive quality standards.

• Ability to work independently and within cross-functional teams.

• Bachelor’s degree in Mechanical, Industrial, or Manufacturing Engineering (Master’s preferred).

• 5+ years of experience in BIW process engineering within the automotive industry.

• GB or BB certification preferred.

• Proven track record in high-volume manufacturing environments, preferably OEM or Tier 1 supplier.