Sr. Process Engineer

Rivian•Normal, IL

10d•Onsite

About The Position

Rivian is seeking a highly motivated and skilled Senior Process Engineer to optimize our manufacturing processes and uphold the highest standards of product quality. The ideal candidate will bridge the gap between process efficiency and quality assurance, driving continuous improvement initiatives and ensuring compliance with industry standards and internal specifications. This role is critical to maintaining high yields, reducing waste, and delivering reliable products to our customers. The Senior Process Engineer position at Rivian will support our Drive Unit production and report to the Process Engineering Manager. This role requires a high level of technical ownership, particularly in the scaling and optimization of drive unit assembly.

Requirements

Bachelor's/Masters degree in engineering discipline
Prefer 3+ years engineering experience in a high-volume manufacturing operation, preferably automotive and/or drive unit/propulsion manufacturing
Creative problem-solving skills
Must have good communication skills – both verbal and written
Hands-on experience with supporting production equipment (Mechanical, electrical, control systems, automation, robotics, etc.)
Experience in using 2D & 3D Modeling tools (AutoCAD, CATIA/ENOVIA)
Experience and/or Knowledge in DOE, Geometric Dimensioning & Tolerance, Torque Tooling, Error Proofing, and PFMEA
Experience and/or certification in Six Sigma DMAIC, Lean Assembly Principles, Time Studies using MTM or MODAPTS
Proficiency in SPC software (Minitab, JMP) for Cp/Cpk analysis
Knowledge of SQL for data extraction is a strong plus
Strong team orientation and cross functional attitude
Ability to stand for 8–12 hours per day
Required to walk, climb, balance, stoop, kneel, crouch, or crawl during equipment troubleshooting
Ability to lift and carry at least 25 pounds

Nice To Haves

Kaizen, 5S, Six Sigma, Lean Six Sigma etc experience is a plus
Availability to work 2nd/night shift
Direct experience with Stator and or Rotor manufacturing processes
Experience in an EV-specific powertrain environment

Responsibilities

Coordinate engineering changes and new program launches
Review, interpret, and summarize statistical data to drive process improvement
Determine the ‘Best Practice’ process approach of material, tooling, equipment, and labor process
Develop and maintain high-quality work instructions, standardized work, process flows, and PFMEAs to ensure manufacturing consistency
Work with design engineering team to develop and establish a design that lends itself to high volume production while ensuring quality during the manufacturing process
Work with manufacturing engineering team to commission and optimize next generation drive unit/propulsion assembly equipment
Perform time analysis using a standard motion time system (MODAPTS), estimate production times, manage staffing requirements, manage labor costs, and drive line balancing
Support production teams through process and equipment related troubleshooting and continuous improvement
Develop recovery/troubleshooting best practices and procedures for production team to increase equipment availability
Investigate assembly issues and implement solutions by reviewing product design, established processes, and equipment/tooling effectiveness
Review, interpret, and summarize statistical data (SPC) to identify trends, reduce scrap, and drive measurable process improvements
Monitor Quality KPI and develop action items to reduce cost with cross functional teams