Sr Process Engineer, DU

Creating exceptional mobility experiences through innovation is at the heart of our mission. Built on proprietary technology and software-defined vehicle architecture, our award-winning vehicles are designed with a “Compromise Nothing™” approach to performance and sustainability, design and engineering, and ambition and integrity. With the company’s flagship models, we strive to redefine the automotive market through deep vertical integration, ensuring excellence in design, engineering, and production across our global facilities.

Position Overview
The Sr Manufacturing Engineer, Drive Unit is responsible for process engineering within a designated section of the DU assembly line at AMP-2, focusing on rotor/stator, gearbox integration, HV wiring, or end-of-line testing. This engineer will build process documentation, PFMEA, control plans, and process capability studies from initial commissioning through volume ramp-up. Accountability for First Pass Yield (FPY), Cpk, and scrap performance in the assigned area is expected, alongside a disciplined approach to change control, objective launch evidence, cross-functional problem-solving, and the transfer of technical ownership to the Saudi workforce.

Key Responsibilities

• DU Process Engineering

  • Own process engineering for a specific section of the DU assembly line.
  • Develop and maintain PFDs, control plans, Standard Work Instructions (SWIs), and set-up standards.
  • Lead process trials, pilot builds, and first-off-tool events in the assigned area.

• Process Capability & FPY Improvement

  • Own Cpk/Ppk and FPY performance for assigned processes.
  • Deploy Design of Experiments (DoE) and structured problem-solving techniques to address chronic losses.
  • Maintain Statistical Process Control (SPC) monitoring and closed-loop process control.

• PFMEA & Control Plans

  • Maintain PFMEA registers and Control Plans for all related robot cell operations.
  • Implement mistake-proofing and poka-yoke strategies for robot cells.

• Equipment & Tooling Support

  • Provide support to Maintenance and Automation on equipment issues impacting process performance.
  • Own tooling design reviews, gauge design, and process fixtures for the assigned area.

• Scrap & Cost Reduction

  • Own the roadmap for scrap reduction in the assigned area, particularly for robotics-related scrap.
  • Drive improvements in cost-per-unit through gains in cycle time, yield, and labor efficiency.

• TPM & Autonomous Maintenance Support

  • Assist in the deployment of Total Productive Maintenance (TPM) across Autonomous Maintenance, Planned Maintenance, and Focused Improvement pillars.
  • Contribute to improving Overall Equipment Effectiveness (OEE), reducing Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR), and developing predictive maintenance strategies.
  • Use MES, IIoT, and data analytics to identify and eliminate losses.

• HV Safety & Compliance

  • Enforce High Voltage (HV) Lockout/Tagout (LOTO), HV Interlock (HVIL) continuity, and mandatory HV Personal Protective Equipment (PPE) for all work on or near EV Powertrain equipment.
  • Ensure compliance with SASO, Saudi MOL, IEC 60204, and functional safety standards (ISO 13849 / IEC 62061).
  • Support HV emergency response protocols, including procedures for thermal runaway isolation and battery-related incidents.
  • Achieve and maintain HV safety competency relevant to the scope of work.

• Launch Governance & Ramp-Up

  • Support Safe Launch activities, run-at-rate events, and capacity verification within your scope.
  • Contribute to Launch Readiness Reviews, Layered Process Audits, and Process Confirmation routines.
  • Participate in Quick Response Quality Control (QRQC) and Root Cause Analysis / Corrective Action (RCCA) escalations during launch and ramp-up phases.

• APQP, Equipment Acceptance & Process Control

  • Maintain comprehensive documentation including PFD, PFMEA, Control Plan, SWI, process specifications, reaction plans, and change records for assigned DU processes.
  • Lead Measurement System Analysis (MSA), capability studies, run-at-rate events, Production Part Approval Process (PPAP), and first-off-tool evidence; define production-release criteria and deviation controls.
  • Develop process parameters and error-proofing techniques for precision fastening, pressing, dispensing, leak testing, electrical tests, NVH, and traceability interfaces.
  • Apply DoE, SPC, and correlation strategies to enhance FPY/Cpk while reducing scrap, rework, cycle time, and warranty risk.

• Launch Governance, Change Control & Operational Readiness

  • Support Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), commissioning, equipment acceptance, Safe Launch, run-at-rate, and capacity verification, ensuring adherence to documented evidence and disciplined punch-list closure.
  • Control all changes related to production, process, software, and testing through a structured risk assessment process, including approvals, validations, revision history, and rollback/containment plans.
  • Engage in readiness reviews, Layered Process Audits, Process Confirmation, and QRQC/RCCA, ensuring timely closure of assigned actions with verified effectiveness.

• Safety, Quality, Data Integrity & Compliance

  • Implement role-specific HV LOTO/HVIL, machine safety, stored-energy isolation, electrical safety protocols, and PPE requirements; never bypass safety devices or product protections.
  • Safeguard product genealogy, calibrated-tool status, test integrity, document control, and audit-ready evidence.
  • Ensure compliance with relevant AMP-2, SASO, Saudi labor/EHS, and IATF 16949 standards and regulations within the assigned scope.

• Saudization, Capability Transfer & Collaboration

  • Foster Saudi national capability through structured On-the-Job Training (OJT), Intermediate Learning Units (ILU)/skills matrices, practical assessments, certification, cross-training, mentorship, and documented knowledge transfer.
  • Develop technical standards, troubleshooting guides, and training materials.
  • Collaborate across various departments including Production, Quality, Maintenance, Automation/Robotics, Manufacturing Engineering, EHS, IT/OT, MES, Supply Chain, Product Engineering, and suppliers.

Skills

• Proficiency in PFMEA, Control Plans, SPC, and PPAP methodologies.
• Capability in DoE and structured problem-solving.
• Strong cross-functional communication skills (Quality, Maintenance, Automation, Production).
• Hands-on execution mindset, particularly in greenfield contexts.
• Competence in technical documentation, structured problem-solving, and risk-based decision-making.
• Data literacy including KPI definition, trend analysis, and evidence-based validation.
• Ability to influence cross-functional teams, coordinate with suppliers, and demonstrate disciplined ownership in a greenfield launch environment.
• Skills in coaching, competency assessment, and knowledge transfer within a multicultural workplace.

Minimum Qualifications

• Bachelor’s degree in Mechanical, Electrical, or Mechatronics Engineering.
• 5 to 8 years of experience in EV or advanced automotive manufacturing, including 3+ years in E-motor manufacturing.
• Proven track record in PFMEA, PPAP, and SPC.
• Proficient in English; proficiency in Arabic is strongly preferred.
• Six Sigma Green/Black Belt certification and experience with greenfield launches and IATF 16949 standards.
• Demonstrated experience in commissioning, FAT/SAT, launch, and high-volume manufacturing ramp within the relevant field.
• Understanding of IATF 16949, APQP/change control, machine/HV safety, and traceability relevant to the role.
• Preferred: Recognized discipline certification, Lean/Six Sigma, greenfield EV/automotive launch experience, and KSA workforce development expertise.

Compensation & Benefits
We offer a comprehensive benefits package that includes medical, dental, and vision insurance; life and disability coverage; paid time off; paid holidays; and a 401(k) retirement plan. Hourly/non-exempt employees can accrue up to 120 hours of paid time off, while salaried/exempt employees can accrue up to 160 hours. Eligible employees may also participate in our equity programs and/or a discretionary annual cash incentive program. Incentives and equity awards depend on individual performance, role scope, market conditions, and overall company results, according to the respective terms.

Equal Opportunity
We believe diversity strengthens everything we build and are proud to be an equal opportunity employer, committed to an inclusive workplace. All qualified applicants are considered without regard to race, color, national or ethnic origin, age, religion, disability, sexual orientation, gender identity or expression, marital status, or any other characteristic protected by applicable laws and regulations.

Accessibility
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