Process Engineer
Location Derabassi - Punjab, India
FORVIA HELLA is a listed international automotive supplier. As a company of the FORVIA Group, FORVIA HELLA stands for high-performance lighting technology and vehicle electronics and, with the Lifecycle Solutions Business Group, also covers a broad service and product portfolio for the spare parts and workshop business as well as for manufacturers of special vehicles. With currently around 36,500 employees at over 125 locations, the Company is active worldwide and generated adjusted sales of €8.1 billion in fiscal year 2024.
YOUR TASKS
Job Title: Process Engineer – Automotive Lighting
Job Summary
The Process Engineer is responsible for designing, developing, optimizing, and maintaining manufacturing processes for automotive lighting systems (headlamps, tail lamps, interior lighting). The role focuses on improving efficiency, ensuring product quality, reducing costs, and supporting new product launches in a fast-paced automotive environment.
Key Responsibilities
1. Process Development & Optimization
Develop and implement manufacturing processes for lighting components (injection molding, assembly, electronics integration).
Analyze existing processes and identify improvements in cycle time, yield, and efficiency.
Apply Lean Manufacturing, Six Sigma, and continuous improvement methodologies.
Optimize workstation layout and line balancing.
2. New Product Introduction (NPI)
Support industrialization of new lighting products from design to mass production.
Participate in Design Reviews (DFM/DFA – Design for Manufacturing/Assembly).
Create process flow diagrams, PFMEA, and control plans.
Coordinate trials, pilot runs, and ramp-up activities.
3. Equipment & Tooling Management
Define specifications for manufacturing equipment and automation.
Support installation, commissioning, and validation of machines.
Troubleshoot equipment/process issues and implement corrective actions.
Work with suppliers for tooling, jigs, fixtures, and automation systems.
4. Quality Assurance
Ensure processes meet automotive quality standards (IATF 16949, ISO 9001).
Monitor KPIs: scrap rate, first-pass yield, OEE.
Lead root cause analysis (8D, Fishbone, 5 Why).
Implement poka-yoke and mistake-proofing solutions.
5. Documentation & Compliance
Prepare and maintain process documentation:
Work Instructions (WI)
SOPs
Control Plans
Process Flow Charts
Ensure compliance with customer-specific requirements (OEM standards).
6. Cross-functional Collaboration
Work closely with R&D, Quality, Production, Maintenance, and Supply Chain teams.
Interface with customers and suppliers during audits and technical discussions.
Support continuous improvement and cost reduction projects.
YOUR QUALIFICATIONS
Required Qualifications Education bachelor’s Degree in:
Mechanical Engineering
Production Engineering
Industrial Engineering
Electronics (preferred for lighting systems)
Experience
5-6 years in automotive manufacturing.
Experience in automotive lighting or plastic/electronics assembly is highly preferred.
Technical Skills
Knowledge of: Injection molding processes (lens, housing)
Ultrasonic welding, laser welding, sealing
SMT/PCB assembly (for LED lighting systems)
Proficiency in: Lean Manufacturing / Six Sigma tools
PFMEA, Control Plans, APQP, PPAP
Familiarity with:
Automation systems and PLC basics
CAD tools (CATIA, NX, SolidWorks) – basic level
Understanding of:
Automotive standards (IATF 16949, VDA 6.3)
Even if you do not meet all our requirements, do not hesitate to apply to us, because the further development of our employees is very important to us and opens up a wide range of opportunities for you in our company.
FORVIA HELLA stands for the variety of all employees. Inclusion and diversity are firmly anchored in our company culture. We are continuously looking for new team players and welcome applications from all interested parties, regardless of their ethical and social background, age, religion, gender, disability, sexual orientation or identity.
HELLA India Lighting Ltd.
Neha Saini
