Sr. Process Engineer, Body in White

We are seeking an experienced and detail-oriented Senior Process Engineer highly skilled and experienced in Body-in-White (BIW) process to lead the development, optimization and implementation of processes. The ideal candidate will bring deep technical expertise in welding, joining technologies, automation and manufacturing systems to ensure production efficiency, high quality and safety in BIW. The successful candidate will drive process capability, ensure product integrity, and support the achievement of shop KPIs.

You Will: 

• Process Development and Optimization
• Design, develop and optimize BIW assembly processes including welding (resistance, laser, MIG, etc.), riveting, gluing, hemming and bolting.
• Define and validate cycle times, line balancing, and takt times for body shop operations. · 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.
• Coordinate build events, trial runs, and quality audits to confirm process and product stability.
• Collaborate with Operations, ME, and Quality to verify line readiness and address early build issues.
• Have good understanding of SPC and line tooling
• Tooling and Equipment
• Specify, source and validate BIW tools, jigs, fixtures and robotics systems.
• Coordinate with equipment suppliers and integrators to ensure compliance with manufacturing and safety standards.
• Support a team of process engineers and specialists across shifts and areas (underbody, framing, closures, etc.).
• Launch and Program Management · Lead process engineering activities for vehicle launch programs.
• Support prototype builds, pre-production trials, and ramp-up to full production.
• Collaborate with cross-functional teams (ME, design, quality, logistics, production) for seamless integration.
• Coordinate process changes and line upgrades with minimal production disruption.
• Quality and Continuous Improvement · Conduct root cause analysis for process-related quality 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. 
• Documentation and Compliance
• Create and maintain detailed process documentation including PFMEA, control plans, work instructions and standard operating procedures.
• Ensure compliance with internal standards, costumer requirements, and regulatory guidelines.
• Understanding of Buy off Book process for handover from Manufacturing Engineering team for operation readiness 6. Mentorship and Leadership
• Provide technical leadership and mentorship to Jr Engineers and technicians.
• Support training and development of shop floor personnel on BIW processes.

You Bring:

• Strong understanding of BIW tooling, fixtures, automation, joining and SPC, processes. 
• Proficient in PFMEA, Control Plans, Process Audits, and quality gates.
• Familiarity with CAD tools, MES systems, and plant-floor digital manufacturing platforms.
• Strong leadership, problem-solving, and cross-functional communication skills.
• Understanding of GD&T, DFM/DFA, quality tools like (G8D, 5why 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).
• 8–10 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.