Process Engineer

AAM - American Axle & Manufacturing•Gallatin, TN

15d•Onsite

About The Position

Dauch is seeking a Process Engineer to join our world-class team. This is an outstanding opportunity to be part of a leading company in the automotive industry, where you will have the chance to contribute to the flawless execution of our manufacturing processes. This role located at our Gallatin plant in Gallatin, TN. The Process Engineer is responsible for coordinating and overseeing all activities related to process control within the Bonding manufacturing process. The Process Engineer needs to be comfortable scaling communication between operators and senior level leaders, along with working on the plant floor.

Requirements

Bachelor’s degree in metallurgical engineering, chemical engineering, materials engineering, or similar.
2+ years of experience, heavy manufacturing or chemical industry preferred.
Proficient in Excel.
Experienced in maintaining proper documentation (training materials, SOPs, FMEA, etc)

Responsibilities

Analyze bonding process performance (yield, scrap rate, UPH, Cp/Cpk) relative to production requirements and customer specifications.
Analyze and audit bonding process failures (e.g., NSOP, weak/low pull strength, lifted bonds, voiding, delamination, misalignment) and develop cost-effective solutions.
Assess the need for bonding process changes based on defect trends, equipment capability, material changes, or new product requirements.
Conduct experiments, DOE, and statistical studies to improve bonding quality, reliability, cost efficiency, and safety performance.
Assist in transferring new bonding technologies, materials, and R&D developments into stable and controlled mass production.
Investigate bonding process trends and correlations, equipment failures, quality system deviations, and reject causes to identify root causes and corrective actions.
Plan and implement bonding process control schemes, including SPC systems, shop floor trials, parameter monitoring, and documentation systems (SOPs, work instructions, control plans, PFMEA).
Establish bonding testing methods (e.g., pull test, shear test, visual inspection standards) and define process control targets.
Implement design or practice changes with hands-on involvement in bonding machine setup, parameter tuning, validation trials, and production support.
Conduct cost/benefit analysis for bonding-related process improvements, automation upgrades, tooling changes, and material substitutions.
Participate as a member of the Internal Quality Audit Team to ensure compliance with internal standards, customer requirements, and industry regulations.
Perform preliminary technical and feasibility evaluations for new bonding equipment, tooling, or process upgrades.
Lead bonding process design, including equipment selection, parameter development, and production line integration.
Prepare cost estimations for bonding-related capital and improvement projects.
Work closely with Engineering and cross-functional teams for capital project development and implementation.
Support supplier qualification and bid evaluation for bonding equipment and materials.
Oversee equipment installation, qualification (IQ/OQ/PQ), debugging, and production ramp-up.
Responsible for training full-time employees, contractors, and agency employees on bonding process standards, equipment operation, troubleshooting techniques, and quality requirements. Develop training materials and ensure operator certification and process compliance
All other duties as assigned.