Process Engineer

Dana · Kariega

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General Job Description:

This staff role supports both existing production operations and new product introduction workstreams. The Process Engineer plays a pivotal role in driving zero-defect quality initiatives, optimising manufacturing processes and equipment performance to achieve plant productivity targets and ensuring the highest standards of safety across all operations.

Success in this position requires strong technical capability, effective communication skills, and a professional approach to working with cross-functional teams and manufacturing processes. We are seeking a driven, results-oriented, and passionate individual who can develop and sustain safe, robust, and highly efficient manufacturing systems while fostering a culture of continuous improvement.

Role & Responsibilities:

• Maintain all PPAP documentation, including PFMEAs, Process Flow Diagrams, Control Plans, Process Sheets, Operator Instructions, and associated manufacturing documentation.
• Develop, specify, implement, and continuously improve manufacturing control systems to ensure safe, robust, and efficient production processes.
• Create, update, and maintain SAP process routings for new product introductions, engineering changes, and model releases.
• Drive continuous improvement of Right First Time (RFT) performance through data analysis, root cause investigation, and process optimisation activities.
• Manage and document process changes in accordance with the site's formal change management procedures and control systems.
• Implement and maintain equipment safety standards, controls, and procedures to ensure safe operation of both new and existing production equipment.
• Develop, maintain, and monitor project timing plans to ensure successful and timely delivery of assigned projects.
• Support departmental objectives through active collaboration and technical assistance to other team members.
• Participate in and contribute to cross-functional APQP activities, design reviews, feasibility studies, and project launch meetings.
• Collaborate with Project Management, Applications Engineering, Design Engineering, Quality, Maintenance, and Production teams to ensure products are designed for manufacture and successfully introduced into production.
• Develop, implement, validate, and industrialise new product variants on existing production lines, ensuring successful completion of APQP gateways from concept validation through PPAP/PSW approval, including customer run-at-rate events.
• Analyse, document, and monitor process capacity, identifying opportunities to improve bottlenecks, cycle times, throughput, and overall equipment effectiveness.
• Ensure all process technical requirements identified within PFMEAs, Control Plans, customer specifications, and project documentation are successfully implemented, validated, and reflected in production processes.
• Maintain action plans, project trackers, and improvement plans to support RFT, safety, quality, productivity, and cost-reduction objectives.
• Attend regular performance review meetings and report progress on safety, quality, productivity, and continuous improvement initiatives.
• Conduct Gauge R&R studies, process capability studies, and poka-yoke validation activities to ensure robust manufacturing processes capable of consistently meeting customer and plant quality requirements.
• Lead and support root cause investigations using structured problem-solving methodologies such as 8D, 5 Why, and Fishbone Analysis.
• Work closely with Maintenance, Controls, and Production teams to improve equipment reliability, eliminate recurring downtime, and enhance process performance.
• Provide technical process support to maintenance and production teams in the diagnosis, troubleshooting, and resolution of equipment and process-related issues.
• Design, develop, and implement simple manufacturing aids, jigs, fixtures, error-proofing solutions, and tooling modifications to improve safety, quality, and productivity.
• Support operator training and process validation activities to ensure adherence to defined manufacturing standards.
• Participate in customer, internal, and third-party audits and support the implementation of resulting corrective actions.
• Lead continuous improvement and cost-reduction initiatives focused on quality, productivity, waste elimination, and operational excellence.

Education & Experience:

• A Degree educated and time served process engineer with hands on experience that uses a systematic approach to problem solving (DMAIC, Red X, 5 Why)
• Experience with APQP, PPAP, PFMEA, Control Plans, MSA, SPC, and process capability analysis.
• Working knowledge of SAP manufacturing systems.
• AutoCAD experience.
• Proficiency in Microsoft Office applications, including Excel, Visio, and Project.
• Strong analytical and structured problem-solving skills.
• Experience within an automotive or high-volume manufacturing environment preferably in driveline assembly.

Core Competencies:

Strategy – Ability to think and act in a strategic way.

• Can lead & act consistent with the company’s strategy and values.
• Able to demonstrate strategic problem solving, good decision making and sound judgement.
• Demonstrates sound business and technical acumen.
• Shows a high degree of intellectual rigor during problem solving.

Talent – Ability to build and develop talent.

• Demonstrates ability to develop self and others.
• Shows evidence of continuous learning.
• Demonstrates performance leadership.

Approach – Ability to demonstrate an effective approach to engagement and problem solving.

• Able to build trust and engage others.
• Can build or contribute to an inclusive team environment.
• Demonstrates strong interpersonal communications.
• Exhibits a strong professional presence.

Results – Ability to achieve planned results.

• Demonstrates a strong customer focus through planning and actions.
• Acts with initiative and urgency.
• Shows the ability to be a change leader with adaptability and continuous improvement.
• Ability to hold oneself and others accountable for results.
• Demonstrates the ability to leverage all available resources to achieve results.

Dana Spicer Axle South Africa (Pty) Ltd is committed to an organizational culture that recognizes and values inclusion and diversity. The Company’s approved Employment Equity Plan and Targets will be considered as part of the recruitment process. You must be fully eligible to live and work in South Africa to apply.

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