Summary

The BIW Underbody Process Engineer is responsible for developing, implementing and optimizing manufacturing processes within the BIW Underbody area to ensure production efficiency, safety and quality standards. This role focuses on process design, validation and continuous improvement of robotic, welding, joining and assembly operations specific to underbody structures in an automotive environment. The successful candidate will drive process capability, ensure product integrity, and support the achievement of shop KPIs.

You Will:

• Design, develop and validate manufacturing processes for the underbody assembly line (front, rear, center and complete) structures.
• Ensure robust process flow, proper cell layout and ergonomic work design.
• Define and optimize welding parameters, gun selection and robot path programming coordination.
• Continuously improve cycle time, process stability and repeatability through data driven analysis.
• Ensure all process documentation (PFMEA, Control Plans, Standard Work, Process Flows) is complete and production ready.
• Coordinate build events, trial runs, and quality audits to confirm process and product stability.
• Collaborate with Operations, ME, and Quality to verify line readiness and address early build issues.
• Specify and approve tooling, jigs, fixtures and welding guns for the underbody line.
• Collaborate with suppliers and tooling engineers during design reviews and buyoffs.
• Support installation and commissioning of new equipment and tooling.
• Maintain equipment documentation and process standards (layout, sequence of operations, torque charts, etc.).
• Define and maintain process parameters to meet dimensional and weld quality requirements.
• Analyze production data to identify process deviations, perform root cause analysis and implement corrective actions.
• Apply lean manufacturing and six sigma methodologies to drive continuous improvement initiatives.
• Capture lessons learned from launches and incorporate them into future programs.
• Ensure process compliance with BIW standards and customer requirements.
• Implement error-proofing solutions and automation enhancements.
• Optimize line balancing to improve throughput and resource utilization.
• Work closely with maintenance, production, quality and automation teams to ensure smooth operation of the underbody line.
• Support daily production meetings and provide process feedback.
• Train production and maintenance personnel on process changes and standard work.
• Interface with product engineering for manufacturability reviews (DFM/DFA).

You Bring:

• Strong understanding of BIW tooling, fixtures, automation, joining and SPC, processes.
• Proficient in PFMEA, Control Plans, Process Audits, and quality gates.
• Familiarity with CAD tools, MES systems, and plant-floor digital manufacturing platforms.
• Strong leadership, problem-solving, and cross-functional communication skills.
• Understanding of GD&T, DFM/DFA, quality tools like (G8D, 5why analysis, and automotive quality standards.
• Ability to work independently and within cross-functional teams.
• Bachelor’s degree in Mechanical, Industrial, or Manufacturing Engineering (Master’s preferred).
• 5–8 years of experience in BIW process engineering within the automotive industry.
• GB or BB certification preferred.
• Proven track record in high-volume manufacturing environments, preferably OEM or Tier 1 supplier.