Process Engineering Manager

Position Overview:

The General Assembly Process Engineering Manager is responsible for leading the GA Process Engineering team through new product introductions, manufacturing readiness, and ongoing production support. The role ensures successful handover of manufacturing processes from Manufacturing Engineering to Operations, validates process capability, and drives robust process control implementation. This position plays a critical role in achieving production KPIs, ensuring product quality, and enabling continuous improvement across the General Assembly shop.

Key Responsibilities:
 o Process Handover and Validation:

• Manage the transition of manufacturing processes from Manufacturing Engineering to Production teams.

• Oversee execution of process and product validation activities including trial builds and line capability studies.

• Ensure readiness of all process documentation such as Control Plans, Standard Work, and Work Instructions.

• Coordinate build audits, fit & finish reviews, and end-of-line validations to confirm process stability.

o Team Leadership and Resource Management:

• Lead, mentor, and develop a team of Process Engineers, Technicians, and Specialists.

• Define priorities and allocate resources across shifts and launch phases.

• Drive capability development and technical growth within the team.

o Process Engineering Excellence:

• Ensure robust process design through ergonomic assessments, torque studies, and fastener validations.

• Implement process control systems, visual management tools, and error-proofing solutions.

• Maintain and continuously improve PFMEAs, Control Plans, Process Flow Diagrams, and Standard Work.

o Quality and Performance KPIs:

• Monitor and improve GA process performance against production KPIs.

• Partner with Quality teams to resolve systemic issues and prevent recurrence.

• Support launch ramp-up activities ensuring stable and capable processes. 

o Problem Solving and Continuous Improvement:

• Lead structured root cause analysis using tools such as 5-Why, Fishbone, and 8D.

• Facilitate cross-functional workshops to enhance process robustness and reduce variation.

• Drive continuous improvement initiatives through Kaizen, benchmarking, and lessons learned.

o Cross-Functional Collaboration:

• Collaborate with Product Engineering, ME, Quality, Logistics, Maintenance, and Operations.

• Participate in launch readiness reviews and program gate approvals.

• Provide GA process input during DFM reviews for new vehicle programs. 

Skills:
o Technical Skills:

• Strong knowledge of GA manufacturing processes and technologies

• Expertise in torque management, fastening systems, and end-of-line testing

• Proficiency in PFMEA, Control Plans, and Layered Process Audits

• Experience with MES systems, torque traceability, BI tools, and CAD software

• Understanding of material flow, kitting strategies, and line balance o Personal Skills:

• Leadership and team development

• Strong analytical and problem-solving capability

• Effective communication and stakeholder management

• Ability to lead under pressure during launch and ramp-up

• High level of ownership and accountability

o Specific Requirements:

• Flexibility to support off-shift and weekend activities during launch phases

• Experience in high-volume automotive production environments preferred 

Minimum Qualifications:

• Bachelor’s degree in industrial Control Engineering, Electrical Engineering, Industrial Automation, or related field

• Minimum 8–10 years of experience in automotive GA process engineering or production leadership

• Proven experience in process validation, equipment handover, and vehicle program launches

• Hands-on experience with problem-solving methodologies and process control systems

• Strong knowledge of manufacturing operations and production readiness