{"id":2041559,"url":"https://alion.io/job/pacgroup-manufacturing-e-motor-process-engineer-2","title":"Manufacturing E-Motor Process Engineer","company":{"id":720692,"name":"Pacgroup","domain":"pacgroup.com","url":"https://alion.io/company/pacgroup","size_band":null,"is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Greenhouse","truth_index":null},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"explicit","locations":["Beirut, Lebanon"],"countries":["LB"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":50000,"max_usd":97000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":9},"experience_years_min":5,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"Python","optional":false}],"status":"live","first_seen_at":"2026-08-18T15:12:57Z","employer_posted_date":"2026-10-07","last_verified_at":"2026-10-08T23:12:07Z","board_verified":true,"closed_at":null,"days_open":51,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":51},"description":"Location: Kingdom of Saudi Arabia (KSA) - 100% Onsite / Relocation Required\nProject Duration: September 2026 - December 2027\nLevel: Senior\nClient Facing: Yes\nContract Type: TBD\nLanguage: English mandatory\nImportant Location & Relocation Requirement\nThis is a long-term, onsite international project based in the Kingdom of Saudi Arabia (KSA), anticipated to run from September 2026 through December 2027. Candidates must be willing and able to relocate to and reside in Saudi Arabia for the duration of the project and work full-time at the client’s manufacturing site. This is not a remote, hybrid, or rotational assignment.\nPlease apply only if you are comfortable relocating to Saudi Arabia and maintaining an onsite presence for the duration of the project.\nAbout The PAC Group\nAt The PAC Group (PAC), we specialize in engineering consulting, program management, and operational excellence, delivering high-impact solutions in more than 20 countries. For more than 41 years, we have partnered with leading companies across the automotive, aerospace, industrial, and technology sectors, providing strategic guidance and hands-on execution that drive innovation and efficiency.\nWhether launching advanced manufacturing systems, deploying digital simulation tools, or scaling global operations, PAC thrives at the intersection of technology, engineering, and problem-solving.\nJoining PAC means joining a dynamic, fast-paced, global team that values curiosity, collaboration, and continuous improvement.\nRole Purpose\nPAC is supporting a client launching an electric drive unit manufacturing line in Saudi Arabia involving the e-motor and inverter through integrated e-drive assembly and end-of-line testing. The line will supply a vehicle assembly plant.\nThe role covers equipment installation and commissioning, process qualification, run-at-rate, PPAP, Start of Production (SOP), and ramp-up to full-volume production.\nWe are recruiting several Process Engineers. Depending on your background, you will take deep ownership of one process area-stator, rotor, motor assembly and test, gearbox, or inverter and power electronics-or work as a cross-process generalist owning an end-to-end value stream.\nCandidates should identify which profile best aligns with their experience so the project scope can be matched accordingly.\nKey Responsibilities\nOwn the process definition for your assigned perimeter, including process flow, cycle-time allocation, parameter windows, control plans, PFMEA, work instructions, and change control from installation through stable-rate production.\nLead equipment commissioning, SAT, process capability studies, and qualification runs; define and execute DOE activities to establish initial parameter windows.\nDeliver APQP and PPAP requirements for your assigned area.\nEngineer to takt by balancing stations and eliminating bottlenecks and micro-stops.\nDrive the production ramp curve by converting scrap, rework, first-pass yield, and downtime data into a prioritized improvement backlog and closing gaps to full-rate production.\nAct as the first-line technical escalation point for production, leading structured problem-solving methodologies including 8D, 5-Why, Ishikawa, and Shainin.\nMake containment decisions in partnership with Production and Quality.\nDesign and validate error-proofing, including poka-yoke, in-line verification, torque and force-displacement monitoring, and part traceability.\nBuild the process data foundation through SPC on critical characteristics, MES and traceability systems, and statistical monitoring.\nSupport customer and supplier interfaces, including sequenced JIT/JIS delivery requirements, customer-specific requirements, supplier PPAP for incoming components, and problem-solving with equipment and component suppliers.\nContribute to safety and compliance activities involving high-voltage work practices, permanent magnet handling, press and laser safety, chemical and adhesive handling, ergonomics, and EHS risk assessments.\nTrain and coach production technicians and operators on process fundamentals, critical parameters, troubleshooting, and reaction plans.\nRequired Qualifications\nMSc or equivalent engineering degree in Mechanical, Electrical, Mechatronic, Manufacturing, Materials, Industrial Engineering, or a related discipline.\nMinimum of 5-10 years of process engineering experience in high-volume manufacturing, ideally within automotive powertrain/components, electric motors, electronics, or comparable takt-driven assembly environments.\nHands-on production-floor experience with direct ownership of a manufacturing process at rate-not solely process design or engineering experience.\nStrong working knowledge of takt-based manufacturing, including cycle-time analysis, line balancing, OEE, bottleneck analysis, and downtime reduction.\nPractical experience using statistical tools including SPC, DOE, MSA/Gage R&R, and capability analysis with tools such as Minitab, JMP, Python, or R.\nStrong command of automotive quality methodologies, including PFMEA, control plans, 8D, root-cause analysis, APQP, and PPAP.\nAbility to work effectively with manufacturing data from MES, SCADA, historians, traceability systems, and test databases.\nStrong written and verbal English communication skills and the ability to confidently defend technical positions with management, customers, and suppliers.\nAbility and willingness to relocate to Saudi Arabia and reside in KSA for the full project duration, anticipated from September 2026 through December 2027.\n Ability to work 100% onsite at the client’s manufacturing facility throughout the assignment.\nPreferred Qualifications\nDirect experience with electric motor, e-axle, or power electronics manufacturing.\nExperience supporting a greenfield launch or major capacity ramp, including commissioning, qualification, run-at-rate, SOP, and ramp to full production.\nIATF 16949 experience and exposure to customer-specific requirements and customer audits.\nExperience supplying a vehicle assembly plant under JIT or JIS sequenced delivery requirements.\nJoining-process expertise relevant to e-drives, including laser welding, ultrasonic or wire bonding, sintering, press-fit, and interference joining.\nTechnical cleanliness experience under ISO 16232 / VDA 19 and ESD control.\nHigh-voltage certification or qualification to work on HV systems.\nLean or Six Sigma certification (Green Belt or Black Belt).\nExperience with automation, robotics, and vision systems.\nPrevious experience working internationally or within the Middle East is beneficial but not required.\nHow You Work\nComfortable operating with ambiguity and incomplete data-a production ramp does not wait for perfect information.\nStrong bias toward the production floor: you go and see, measure, investigate, and build conclusions from evidence.\nRigorous about documentation and change control because a process that is not documented cannot effectively be transferred or scaled.\nCollaborative across functions and cultures and able to maintain and defend a technical position under pressure.\nComfortable working as part of an international, multicultural team while embedded onsite with the client.\nWhat Success Looks Like\nYour process area is qualified, run-at-rate is passed, and PPAP is submitted and approved according to customer timing.\nStations within your perimeter maintain net cycle time within takt allocation, with OEE meeting or exceeding the ramp plan.\nFirst-pass yield follows the planned ramp curve, with top scrap and rework drivers ranked, understood, and actively addressed.\nZero customer line stoppages attributable to your process area; any escape has a verified root cause and permanent countermeasure rather than containment alone.\nProcess documentation-including control plans, PFMEA, work instructions, parameter windows, and reaction plans-is complete, current, and actively used by production.\nProduction technicians within your area are capable of operating and troubleshooting the process independently.\nWorking Conditions & International Assignment Requirements\nThis position requires relocation to and residence in the Kingdom of Saudi Arabia for the duration of the project, currently anticipated from September 2026 through December 2027.\nThe position requires full-time, 100% onsite presence at the client’s manufacturing facility in Saudi Arabia.\nThis is not a remote, hybrid, fly-in/fly-out, or rotational assignment.\nCandidates must be prepared to establish temporary residence in Saudi Arabia for the project period.\nRegular to full-time work will occur within production areas, dry rooms, and cleanrooms with associated PPE and gowning requirements.\nDuring commissioning, qualification, SOP, and ramp phases, flexibility in working hours and periodic shift or weekend support will be expected.\nNo routine travel to equipment suppliers, partner plants, or R&D sites is currently anticipated.\nInternational assignment and work authorization requirements will apply based on candidate eligibility and project requirements.\nWhat We Offer\nCompetitive salary/package plus completion bonus.\nThe opportunity to play a key role in a major international greenfield manufacturing launch.\nA launch you can point to throughout your career: taking a manufacturing operation from installation and commissioning through SOP and full-rate production.\nStructured training on technology and process methods, with exposure to the full manufacturing value stream.\nThe opportunity to work directly with an international client and cross-functional engineering teams on a high-profile project in Saudi 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