Process Design Engineer (Automotive)

We're ALTEN Technology USA, an engineering company that provides solutions for engineering, technology, and product development projects. For decades, we've been helping our clients develop products that are changing the world, whether that's by shaping the future of space exploration, saving lives with medical devices that set a new standard of care, or creating the fully autonomous electric taxi of tomorrow. Our team of more than 600 people works across industries including aerospace, medical devices and life sciences, unmanned systems and robotics, automotive OEM and tier 1 suppliers, commercial vehicle, electric vehicles, rail, and more. Our offices across the US have different industry focuses and engage with our clients in different ways, ranging from working on-site at client facilities to performing product development at our delivery centers.

ALTEN Group, our parent company, has been a leader in engineering and information technology for more than 30 years. ALTEN Group operates in 30 countries across Europe, North America, Asia, Africa and the Middle East and employs more than 36,000 people, 88% of whom are engineers. The company covers the whole development cycle and offers a choice of service levels, from technology consulting to complete project outsourcing.

When you join ALTEN Technology USA, you join a group of people passionate about collaborating to solve some of the world's most technical engineering challenges. Our success is tied to taking care of our employees by building relationships and providing opportunities for mentorship and career growth. We offer comprehensive benefits for all full-time employees, including medical, dental, and vision insurance; a 401(k) plan with employer matching; paid time off (PTO); paid parental leave; and mentorship to help you take your career to the next level. You don't have to take our word for it that we are a great place to work—we were named on the 2023 Top Workplaces list thanks to feedback from our proud employees.

For a quicker response, send your resume to [email protected] or apply directly on LinkedIn!

Role Overview

Looking for a Process Design Engineer to support automation and lean manufacturing for our business. This position will play a crucial role in driving operational excellence, process optimization, and innovation in our manufacturing processes. Responsible for developing and implementing advanced manufacturing strategies, leading cross-functional teams, and driving continuous improvement initiatives. The ideal candidate will bring deep expertise in Power product manufacturing processes and proven ability to deliver continuous improvement in a dynamic, international environment.

RESPONSIBILITIES

• Lead the New product process design, develop, and implement manufacturing processes for power products, including UPS systems, DC power supplies, (Future include also Thermal product) and related components, from prototype to full-scale production.
• Conduct process simulations, feasibility studies, and risk assessments to optimize production workflows, reduce cycle times, and improve overall equipment effectiveness (OEE).
• Apply DFM/DFA methodologies to review product designs, identify potential manufacturing issues early in the development cycle, and recommend modifications for ease of assembly, cost reduction, and quality enhancement.
• Collaborate with design engineers to ensure new power product designs are manufacturable, incorporating feedback on materials, tolerances, and assembly techniques.
• Lead root cause analysis for production issues, implementing corrective actions and preventive measures using tools like FMEA (Failure Mode and Effects Analysis) and Six Sigma.
• Develop and maintain process documentation, including standard operating procedures (SOPs), work instructions, and process flow diagrams.
• Oversee the selection, installation, and validation of manufacturing equipment and tooling specific to power electronics assembly, such as soldering, PCB fabrication, and enclosure assembly.
• Monitor and analyze production metrics to identify opportunities for process improvements, cost savings, and waste reduction.
• Ensure compliance with industry standards, safety regulations, and quality certifications (e.g., ISO 9001, UL for power products).
• Mentor junior engineers and production staff on best practices in manufacturing processes and DFM/DFA.

Skills

• Proficient in executive communication and presentation.
• Familiarity with ERP systems (e.g., SAP) and manufacturing execution systems (MES).
• Experience in high-volume production environments for power products in Asia-Pacific regions.
• Knowledge of sustainability practices in manufacturing, such as eco-friendly materials and energy-efficient processes.

EDUCATION AND CERTIFICATIONS

• Bachelor's degree in mechanical engineering, Electrical Engineering, Manufacturing Engineering, or a related field; master's degree preferred.
• Minimum of 5 + years of hands-on experience in manufacturing process design for power products, specifically UPS, DC power systems, or similar electronics.
• Extensive expertise in DFM/DFA demonstrated success in applying these principles to reduce manufacturing costs and improve product reliability.
• Strong knowledge of power electronics manufacturing techniques, including PCB assembly, thermal management, component sourcing, and testing protocols.
• Proficiency in CAD software (e.g., SolidWorks, AutoCAD) for process design and simulation tools (e.g., Arena, FlexSim).
• Experience with lean manufacturing principles, Kaizen events, and continuous improvement methodologies.
• Excellent problem-solving skills, with the ability to analyze complex data and make data-driven decisions.
• Strong communication and teamwork abilities to work effectively in a multicultural, cross-functional environment.

ALTEN Technology is an Equal Opportunity Employer. Our Policy is to extend opportunities to qualified applicants and employees on an equal basis regardless of an individual's age, race, color, sex, religion, national origin, disability, sexual orientation, gender identity/expression or veteran status.

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