Senior Process Engineer

Responsibilities:

1. People Management

• Guide, coach, and train technicians on machine operations, processes, and technical standards.

• Support the development and technical onboarding of new Process Engineers and Engineering Assistants.

• Provide technical leadership to engineering teams and drive effective workload planning and resource utilization.

• Foster a collaborative, performance-driven team environment focused on safety, quality, productivity, and continuous improvement.

2. New Equipment Installation & Process Setup

• Collaborate with cross-functional teams to develop and execute project plans for new equipment installation, commissioning, and process setup.

• Lead the integration of new equipment into existing manufacturing processes, ensuring seamless compatibility and operational readiness.

• Follow up on machine qualification, commissioning activities, and performance validation.

• Ensure all relevant machine manuals, technical specifications, operating procedures, and documentation are properly established and maintained.

• Evaluate the robustness of existing processes and introduce fact-based, technically sound improvements.

• Lead and implement process changes based on engineering expertise and data-driven analysis.

• Develop, maintain, and champion PFMEA for all critical manufacturing processes.

3. Process Transfer & Stabilization

• Ensure processes transferred from other manufacturing sites are properly documented, evaluated, qualified, and adapted to the local manufacturing environment.

• Provide technical support for process quality, standardization, and product/process industrialization.

• Liaise with Headquarters and other manufacturing sites to facilitate knowledge transfer and continuous process improvement.

• Drive process stabilization and further optimization following process transfers and new product introductions.

4. Process Control

• Monitor and analyze SPC charts in real time and lead troubleshooting activities for process deviations and non-conformances.

• Work closely with Production and Maintenance teams to investigate and resolve production lots on hold.

• Identify opportunities to optimize manufacturing cycle times by eliminating redundant or non-value-added process steps.

• Monitor process data and trends against in-process specifications using SAP, PDA, SPC, and other analytical tools.

• Ensure effective process controls are established and maintained to achieve consistent product quality and process capability.

5. Real-Time Manufacturing Support

• Provide timely technical support for real-time production issues and implement effective corrective and preventive actions.

• Develop and implement tools, process specifications, procedures, and TPM practices to support manufacturing operations.

• Analyze production problems using historical data, past cases, and cross-functional input to determine effective solutions.

• Work closely with Equipment Engineering to troubleshoot and resolve machine-related issues.

• Investigate customer complaints and claims, support root-cause analysis, and develop effective corrective actions and new technical solutions.

• Provide hands-on technical support on the shop floor to minimize yield losses, quality risks, and production interruptions.

6. Lean & Continuous Improvement

• Promote and champion a Lean culture within the manufacturing organization.

• Facilitate and actively participate in Lean, Six Sigma, and continuous improvement projects.

• Identify opportunities to improve process efficiency, productivity, quality, and cost.

7. Training & Development

• Develop and deliver technical training to technicians on existing and new manufacturing processes.

• Train and mentor new Engineering Assistants and Process Engineers.

• Transfer technical knowledge and best practices to strengthen overall engineering and manufacturing capabilities.

8. Ad Hoc & Special Assignments

• Support ad hoc assignments and projects as directed by the Head of Department.

• Participate in special technical assignments, equipment installations, process setup, commissioning, and troubleshooting activities at other manufacturing sites when required.

• Provide technical expertise and support during critical plant or process improvement projects.

Requirements

Education & Experience

• Bachelor’s Degree in Mechanical Engineering, Electrical Engineering, Materials Science, or a related engineering discipline.
• Minimum 5 years of relevant experience as a Process Engineer, preferably with experience in machine commissioning, process setup, and manufacturing engineering.
• Experience in cold rolling will be a strong advantage.
• Knowledge and hands-on experience in non-ferrous metal processing, particularly rolling, annealing, slitting, and stamping, is essential.
• Experience in precision manufacturing and process industrialization is an advantage.

Technical & Analytical Skills

• Strong technical problem-solving, analytical, and critical-thinking skills.
• Strong understanding of process control and data analysis.
• Proficient in problem-solving methodologies and tools such as SPC, DOE, FMEA, Lean, and Six Sigma.
• Strong ability to analyze process data, identify trends, determine root causes, and implement sustainable corrective actions.
• Basic knowledge of SAP, particularly material management and production-related functions.
• Strong shop-floor technical expertise with the ability to make timely decisions to resolve engineering and manufacturing problems while minimizing yield and quality risks.
• Ability to understand and optimize complex manufacturing processes and equipment.
  
• Personal & Communication Skills
• Strong communication skills with the ability to communicate effectively with employees at all organizational levels.
• Strong interpersonal and teamwork skills with the ability to organize, coordinate, and facilitate cross-functional activities.
• Self-motivated, proactive, and willing to continuously develop knowledge in metal processing technology and precision engineering.
• Strong ownership and commitment to achieving operational and engineering objectives.
• Willingness to work flexible hours, including long or non-standard working hours when required to support critical manufacturing activities.
• Fluent in spoken and written English.
• Knowledge of German at conversational level will be an added advantage.
  
  Key Competencies
  • Process Engineering & Industrialization
  • Machine Commissioning & Qualification
  • Cold Rolling & Non-Ferrous Metal Processing
  • Process Control & Statistical Analysis
  • Root Cause Analysis & Problem Solving
  • PFMEA, SPC, DOE & Lean Manufacturing
  • Continuous Improvement
  • Cross-Functional Leadership
  • Technical Training & People Development
  • Shop-Floor Technical Support