Sr Process Engineer, DU

Position Overview

The Sr Manufacturing Engineer, Drive Unit owns process engineering for an assigned section of the DU assembly line at AMP-2 — covering rotor/stator, gearbox integration, HV wiring, or EOL test. Joining at facility launch, this engineer builds process documentation, PFMEA, control plans, and process capability studies from first commissioning through volume ramp-up. The role is accountable for FPY, Cpk, and scrap performance in the assigned area. The role operates through disciplined change control, objective launch evidence, cross-functional problem solving, and structured transfer of technical ownership to the Saudi workforce.

Key Responsibilities

·                DU Process Engineering

·                Own process engineering for an assigned DU line section

·                Develop and maintain PFDs, control plans, SWIs, and set-up standards

·                Lead process trials, pilot builds, and first-off-tool events for assigned area

Process Capability & FPY Improvement

·                Own Cpk/Ppk and FPY performance for assigned processes

·                Deploy DoE and structured problem-solving on chronic losses

·                Maintain SPC monitoring and closed-loop process control

PFMEA & Control Plans

·                Maintain PFMEA registers and Control Plans for all related robots cell / operations

·                Implement poka-yoke and mistake-proofing robots cell

Equipment & Tooling Support

·                 Support Maintenance and Automation on equipment issues affecting process performance

·                 Own tooling design reviews, gauge design, and process fixtures for assigned area

Scrap & Cost Reduction

·                 Own scrap reduction roadmap for assigned area / robotics related scrap

·                 Drive cost-per-unit improvement through cycle time, yield, and labor efficiency

TPM & Autonomous Maintenance Support

·                Support TPM deployment across Autonomous Maintenance, Planned Maintenance, and Focused Improvement pillars

·                Contribute to equipment OEE improvement, MTBF/MTTR reduction, and predictive maintenance strategies

·                Leverage MES, IIoT, and historian analytics to identify and eliminate losses

HV Safety & Compliance

·                Enforce HV LOTO, HVIL continuity, and mandatory HV PPE for all work on or near EV Powertrain equipment

·                Comply with SASO, Saudi MOL, IEC 60204, and functional safety standards (ISO 13849 / IEC 62061)

·                Support HV emergency response including thermal runaway isolation and battery-related incident procedures

·                Achieve and maintain HV safety competency appropriate to scope of work

Launch Governance & Ramp-Up

·                Support AMP-2 Safe Launch activities, run-at-rate events, and capacity verification within scope

·                Contribute to Launch Readiness Reviews, Layered Process Audits, and Process Confirmation routines

·                Participate in QRQC / RCCA escalations during launch and ramp-up phases

APQP, Equipment Acceptance & Process Control

·                Maintain coherent PFD, PFMEA, Control Plan, SWI, process specifications, reaction plans and change records for assigned DU processes.

·                Lead MSA, capability, run-at-rate, PPAP/PSW and first-off-tool evidence; define production-release criteria and deviation controls.

·                Develop process windows and error-proofing for precision fastening, pressing, dispensing, leak test, electrical test, NVH and traceability interfaces.

·                Use DoE, SPC and correlation to improve FPY/Cpk and eliminate scrap, rework, cycle and warranty risk.

Launch Governance, Change Control & Operational Readiness

·                Support FAT/SAT, commissioning, equipment acceptance, Safe Launch, run-at-rate and capacity verification with objective evidence and disciplined punch-list closure.

·                Control production, process, software and test changes through documented risk assessment, approvals, validation, revision history and rollback or containment planning.

·                Participate in readiness reviews, Layered Process Audits, Process Confirmation and QRQC/RCCA; close assigned actions with verified effectiveness.

Safety, Quality, Data Integrity & Compliance

·                Apply role-specific HV LOTO/HVIL, machine safety, stored-energy isolation, electrical safe-work and PPE requirements; never bypass safety devices or product protections.

·                Protect product genealogy, calibrated-tool status, test/measurement integrity, document control and audit-ready objective evidence.

·                Comply with applicable AMP-2, SASO, Saudi labor/EHS, IATF 16949, IEC 60204 and functional-safety requirements within assigned scope.

Saudization, Capability Transfer & Collaboration

·                Build Saudi national capability through structured OJT, ILU/skills matrices, practical assessment, certification, cross-training, mentorship and documented knowledge transfer.

·                Create technical standards, troubleshooting guides and training material

·                 Collaborate across Production, Quality, Maintenance, Automation/Robotics, Manufacturing Engineering, EHS, IT/OT, MES, Supply Chain, Product Engineering and suppliers.

Skills

·                PFMEA, Control Plan, SPC, and PPAP fluency

·                DoE and structured problem-solving capability

·                Effective cross-functional communicator (Quality, Maintenance, Automation, Production)

·                Hands-on execution mindset in greenfield contexts

·                Technical standards, structured problem solving, risk-based decision making and controlled documentation

·                Data literacy: KPI definition, trend analysis, evidence-based validation and clear executive/shop-floor communication

·                Cross-functional influence, supplier coordination and disciplined ownership in a greenfield launch environment

·                Coaching, competency assessment and knowledge transfer in a multicultural workplace

Minimum Qualifications

·                Bachelor's degree in Mechanical, Electrical, or Mechatronics Engineering

·                5 to 8 years in EV or advanced automotive manufacturing, and 3+ years in E-motors manufacturing

·                Demonstrated PFMEA, PPAP, SPC track record

·                Fluent in English; Arabic strongly preferred

·                Six Sigma Green/Black Belt; greenfield launch; IATF 16949

·                Demonstrated experience with commissioning, FAT/SAT, launch, production readiness or high-volume manufacturing ramp within the role discipline

·                Working knowledge of IATF 16949, APQP/change control, machine/HV safety and traceability requirements applicable to the role

·                Preferred: recognized discipline certification, Lean/Six Sigma, greenfield EV/automotive launch and KSA workforce-development experience