Job Description

We are seeking a Process Engineer to lead and control two Varnish coating processes for two different modules within the eMotor project. In this role, you will be responsible for ensuring product quality and process consistency by utilizing resistance induction heating processes to heat production parts, managing varnish dripping characteristics, implementing specialized gauges, and training production personnel. This position is heavily supported by quality engineering tools (DFMEA, PFMEA, Control Plan, Process Illustration, Part Print and Reaction Plan) to implement the SPC strategy, manage scrap reduction due to common cause variation, and report monthly process capabilities, while maintaining effective communication with Production, Maintenance, Quality, PTME, Suppliers and OEM.

• Varnish Process Control (2 Modules): Ensure and control the varnish coating process across two different modules, meeting technical specifications for dripping, coverage, and adhesion.
• Resistance Induction Heating: Control and optimize the induction heating process (via resistors) used to heat production parts prior to and during varnishing.
• Gauges & Measurement: Design, implement, and maintain gauges and control devices specific to the varnish application to guarantee product quality.
• Personnel Training: Train, coach, and certify production personnel on varnish process standards, operating procedures, and reaction plans.
• Technical & Quality Documentation: Continually develop, update, and validate DFMEA, PFMEA, Control Plan, Process Illustration, and Part Print, with a focus on varnish process variations.
• SPC Strategy and Reporting: Implement and oversee the SPC strategy (sampling design, control charts, variability analysis, and Cp/Cpk – Pp/Ppk calculation) and prepare monthly capability reports.
• Monitoring and Improvement of Quality Metrics: Regularly monitor and optimize key metrics such as First Time Through (FTT) and Rolled Throughput Yield (RTY).
• Scrap Reduction: Design and execute action plans focused on reducing process scrap by resolving key issues related to common cause variation in the varnish process.
• Engineering Change Management and Reaction Plans: Lead Engineering Change Management (MTC) and structure robust reaction plans for process deviations.
• Problem Solving and Lean Manufacturing: Apply structured methodologies (Global 8D, Six Sigma, or equivalent) and Lean Manufacturing tools (including Value Stream Mapping - VSM).
• Ergonomics and Process Robustness: Conduct ergonomics studies on workstations and implement Poka Yoke and Error Proofing systems to prevent operational or coating errors.
• Process Audits: Actively participate in process and quality system audits (such as ISO 9001 and IATF 16949) to ensure compliance.
• Cost Reduction: Propose and implement continuous improvement ideas to reduce manufacturing costs and varnish consumption without compromising quality.
• Consumables Management: Identify, classify, and maintain optimal levels of consumables (varnish, filters, etc.) and product-contact parts to ensure operational continuity.
• Cross-Functional Collaboration: Work in synergy with Production, Maintenance, Quality, PTME, and external suppliers to resolve issues and meet project milestones.
• Professional Reporting: Prepare professional-grade reports and presentations to clearly explain issues, investigations, and corrective actions to management and involved areas.

Education

• Bachelor’s degree in Engineering (Mechanical, Industrial, Chemical, Materials, Mechatronics, or a related field).

Experience

• Strong, demonstrable experience in coating or varnishing processes, preferably in the automotive sector, electric motors, or high-precision industrial components.
• Experience managing two distinct modules or production lines is highly valued.

Languages

• Fluent English (B2/C1 level equivalent), with excellent technical communication, reading, and writing skills.

Technical Knowledge

• Proficiency with resistance induction heating processes for metal parts.
• Deep understanding of varnish application, dripping characteristics, curing, and quality control.
• Experience designing and implementing process gauges and measurement devices.
• Ability to train and upskill operators and production staff.
• Proficiency with Core Tools (DFMEA, PFMEA, Control Plan, MSA, SPC).
• Advanced ability to interpret technical drawings (Part Prints) and Process Illustrations.
• Statistical Process Control (SPC) and Process Capability analysis (Cp/Cpk – Pp/Ppk).
• Structured problem-solving methodologies (Global 8D, Six Sigma, or equivalent).
• Lean Manufacturing tools and Process Mapping (Value Stream Mapping).
• Poka Yoke and Error Proofing design.
• Knowledge of quality standards and audits (ISO 9001 / IATF 16949).
• Ergonomics applied to production lines.
• Monitoring and improving quality KPIs (FTT, RTY).

Soft Skills

• Analytical thinking and complex problem-solving abilities.
• Leadership, proactivity, and a results-driven mindset.
• Strong communication and technical writing skills.
• Ability to work effectively in cross-functional, multidisciplinary teams.

DISCLAIMER: Ford Motor Company is an Equal Opportunity Employer, as we are committed with a diverse workforce, and do not discriminate against any employee or applicant for employment because of race, color, sex, age, national origin, religion, sexual orientation, gender identity and/or expression, status as a veteran and basis of disability.