Senior Process Engineer

• Development and implementation of Global Tooling systems for manufacturing Engine component within Power train operations.

• Develop and implement the process to do the latest Tool designs and adhere the innovative technology for safety and ergonomics

• Aligned to standard Bill of Process strategies through system inquiry, simultaneous engineering, build, installation, and commissioning phases for the flawless launches.
• Implement tooling strategy in line with manufacturing process and train the team to adhere the requirement.

• Interface with Product design to evaluate Manufacturing feasibility, and incorporate Lean Principles on development requests.

• Develop the processes of including Latest tooling, Minimum Quantity lubrication improvements and tool Management software during the launch phase of the program.

• To implement continuous improvement of tooling processes and introduction of new cutting edge technologies for the process optimization and continuous cost reduction.

Develop the Master schedule for tooling process and guide the team for cost reduction implementation

Deliver Manufacturing systems:

• Lead in developing the Global tooling technology for a new Engine plant in accordance with Ford Powertrain New Model Launch, Quality and Core Engineering Powertrain Standards, Strategies, Bill of Process, Procedures and Guidelines
• Responsibility for design, approve, runoff, delivery and launch the Cutting tools, also Plan and facilitate the tool crib to support New Programs
• Prepare & send RFQ to OEM and Tier 1 suppliers for the tooling requirement & get quotation from various suppliers to do the cost comparison study. Select the best supplier to complete the ordering process.
• Lead in developing detail technical specifications are shared with supplier. Lead pre-witness at supplier end to identify the areas of improvement before the tool ordering process and consider the service and support possibilities of the organization after the delivery or during the issues.
• Lead the drawing approval process and DFMA along with the Process sheets and work closely with Machine vendor and GMS team for Tool layout approval.
• Lead the machine prove out activities at the supplier floor before final witness and lead the process improvement activities before completing the Vendor run off. Monitor the Cycle time on all the process as per the RFQ.
• Lead the installation & commissioning of all the Machines at the plant. Conduct witness after installation & prove out as per the requirements. Co-ordinate PROTAG sign-off for all the machines tooling requirement & Lead Machine Acceptance Checklist (MAC) sign-off and issue resolution.
• Lead coordination of CFT team (Process, Product development, gauging, Productivity) for Machine prove out and tool change capability.
• Lead development of process documentation (e.g. DCP, PFMEA, Process Sheets, Process Illustrations, tool set up drawings, etc.) for all Machines.
• Lead and ensure on time delivery of all OEM documentation for tooling (e.g. tool drawings, tool layouts and cycle charts.)
• Lead the PTR issues and ECCAR issues related tooling and tooling improvement during the capability.
• Lead the process development activities through the tooling to improve the current process and Job#1 plus 90 days support.

Key Responsibilities

• Cutting Tool Design & Selection: Select, specify, and design cutting tools (inserts, end mills, drills, reamers, taps, broaches, grinding wheels) optimized for specific materials and machining operations
• Process Optimization: Analyze machining parameters (speeds, feeds, depth of cut) to maximize tool life, minimize cycle time, and improve surface finish quality
• Tool Life & Wear Analysis: Monitor and analyze tool wear patterns, failure modes, and performance data to drive continuous improvement in tooling strategy
• Troubleshooting: Diagnose and resolve cutting tool-related issues on the shop floor, including chatter, chipping, premature wear, and dimensional inconsistencies
• New Program Support: Support new part/program launches by developing tooling packages, conducting feasibility studies, and validating tool performance during prototype and production trials
• Vendor Collaboration: Work with cutting tool suppliers to evaluate new tooling technologies, negotiate pricing, and manage tool procurement and delivery timelines
• CAM Programming Support: Collaborate with CNC programmers to optimize toolpaths and cutting strategies for efficient material removal
• Cost & Inventory Management: Track tooling consumption, manage tool crib inventory, and identify cost-reduction opportunities through standardization or alternative tooling solutions
• Documentation: Maintain tooling standards, specifications, cutting parameter sheets, and tool life data

Diploma or Degree in -Automotive, Engineering-Electrical, Engineering-Industrial, Engineering-Manufacturing, Engineering-Mechanical, Engineering-Other, Engineering-Production. Master of Science preferred