Process Design Engineer

ALTEN Technology USA•Detroit, MI

19h

About The Position

We’re ALTEN Technology USA, an engineering company helping clients bring groundbreaking ideas to life—from advancing space exploration and life-saving medical devices to building autonomous electric vehicles. With 3,000+ experts across North America, we partner with leading companies in aerospace, medical devices, robotics, automotive, commercial vehicles, EVs, rail, and more. As part of the global ALTEN Group—57,000+ engineers in 30 countries—we deliver across the entire product development cycle, from consulting to full project outsourcing. When you join ALTEN Technology USA, you’ll collaborate on some of the world’s toughest engineering challenges, supported by mentorship, career growth opportunities, and comprehensive benefits. We take pride in fostering a culture where employees feel valued, supported, and inspired to grow. Client is 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.

Requirements

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.

Nice To Haves

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.

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.